CN105829024A

CN105829024A - Maker apparatus for coated abrasive article

Info

Publication number: CN105829024A
Application number: CN201480070196.XA
Authority: CN
Inventors: 斯科特·R·卡勒; 约翰·T·博登; 史蒂文·J·凯佩特; 尼格斯·B·艾德弗里斯; 卡兰·因达尔; 阿龙·K·尼纳贝尔; 戴维·L·莫里森; 彼得·T·本森; 普拉蒂克·普拉内; 布拉德福德·B·赖特
Original assignee: 3M Innovative Properties Co
Current assignee: 3M Innovative Properties Co
Priority date: 2013-12-23
Filing date: 2014-12-22
Publication date: 2016-08-03
Anticipated expiration: 2034-12-22
Also published as: EP3086903A1; US20160311081A1; WO2015100220A1; CN105829024B; EP3086903A4; US10675734B2; US10518388B2; EP3086903B1; US20200139512A1

Abstract

The invention discloses a maker apparatus for a coated abrasive article. The maker apparatus includes a first web path and a second web path. The first web path is used for guiding a production tool such that it wraps a portion of the outer circumference of an abrasive particle transfer roll. The second web path for a resin coated backing guides the resin coated backing such that it wraps a portion of the outer circumference of the abrasive particle transfer roll with the resin layer positioned facing the dispensing surface of the production tool this is positioned between the resin coated backing and the outer circumference of the abrasive particle transfer roll. Abrasive particles are transferred from cavities in the production tool to the resin coated backing as the resin coated backing and the production tool traverse around the abrasive particle transfer roll

Description

The draft machine equipment of coated abrasives

Technical field

The present invention refers broadly to abrasive grain and the method using these abrasive grains to prepare various goods.

Background of invention

Generally it is coated on the backing of resin coating prepare coated abrasives by abrasive grain by drop coating or electrostatic coating method.In both approaches, it is usually preferred to electrostatic coat method, because the granule that this method is not 1 for aspect ratio provides a certain degree of tropism control.In general, the location of abrasive grain and orientation and cut point thereof are extremely important to the performance determining abrasive material.

PCT International Publication WO2012/112305A2 (Keipert) discloses the coated abrasives by using accurate screen cloth to manufacture, this precision screen cloth has non-circular hole that is the most spaced apart and that align, each abrasive grain to be immobilizated in fixed position, and can be used for the surface features of the abrasive grain that rotation into alignment is rotationally oriented with specific z-direction.In this approach, screen cloth or perforated plate are laminated to binder film and are filled with abrasive grain.Can by screen cloth geometry with limit abrasive grain and contacted by screen openings and be attached to the ability of binding agent and control the orientation of abrasive grain.Remove adhesive phase from the screen cloth filled and the abrasive grain of orientation can be transferred to abrasive material backing with upside down.The premise of this method is to there is binding agent, but this may make troubles, binding agent elapses in time and is prone to antiseized (such as, due to dust deposit), and binding agent can be transferred to gained coated abrasives, this may make binding agent transfer to workpiece and pollute workpiece.

Summary of the invention

For triangle abrasive grain, it is inverted the cutting and life-span generally to abrasive product (especially to metal such as rustless steel) of (base portion the is upward) abrasive grain and there is negative effect.Causing local pressure relatively low due to high bearing area and make these be inverted abrasive grain bad fracture occurs, therefore occur that metal blocks, this can shorten cutting life.In conventional belt coated abrasive product, it is inverted abrasive grain ratio and depends primarily on mineral coating weight, be therefore difficult to realize high mineral in the case of there is not inversion abrasive grain and cover.This makes to use the very open coat structure being generally of sub-optimal performance.

Abrasive grain is the most critically important relative to the orientation of cut direction.Cutting efficiency and abrasive grain fracture mechanism are different with orientation.For triangle shaped abrasive granule, for improving cutting and puncturing, it is usually preferred that the relative motion of abrasive product and/or workpiece makes the edge of triangle be presented in cutting movement rather than on the face of triangle.If presenting facing to cut direction of triangle, then triangle will generally rupture near base portion and outside ground flat.

In abrasive product, the spacing of abrasive grain is the most critically important.Conventional method (such as drop coating and electrostatic precipitation) provides the spacing of random distribution, particle agglomeration the most often occurs, and the most two or more shaped abrasive granules are finally contacting with each other near the tip of shaped abrasive granule or upper surface.Owing to bearing area local increases and in use due to the most mechanical enhancement effect, in cluster, shaped abrasive granule can not correctly rupture and puncture in these regions, therefore, reunite and cause cutting performance to be deteriorated.Compared to the coated abrasives of the shaped abrasive granule with evenly spacing, reunite and cause less desirable heat to gather.

In accordance with the above, it is desirable to there is simple, the alternative method of economical and efficient and device that can be used for positioning and be orientated abrasive grain (especially shaped abrasive granule) in coated abrasive goods.

For meeting the demand, the invention provides the solution of practicality, therefore, coiled material or instrument that the shape and size that the screen cloth of WO2012/112305A2 (Keipert) has been accurately reproduced over time are complementary with the abrasive grain being applied are substituted.This complementary shape substantially increases fills abrasive grain in high-speed production and is retained the tendency of abrasive grain by chamber.And avoid using the adhesive phase shown in WO2012/112305A2 (Keipert), greatly simplify coating procedure.

In some embodiments, the present invention relates to the draft machine equipment of a kind of coated abrasives, including:

First web path, this first web path is for having the tool of production on the distribution surface including multiple chamber, this first web path guides the tool of production by coated abrasives draft machine equipment so that a part for the excircle of this tool of production winding abrasive grain transferring roller；

Second web path, this second web path is for the backing of resin coating, this second web path guides the backing of resin coating by coated abrasives draft machine equipment, the backing that this resin is coated winds a part for the excircle of abrasive grain transferring roller, and wherein the resin bed of the backing of resin coating is positioned at towards distribution surface alignment and this tool of production between backing and the excircle of abrasive grain transferring roller of resin coating；And

Abrasive grain feeder, before this abrasive grain feeder is positioned at abrasive grain transferring roller with this tool of production along the direction that the first web path is advanced, to be assigned to abrasive grain distribute on surface and in multiple chamber；And

Wherein when the backing that resin coats and the tool of production turn round around abrasive material, abrasive grain is transferred to the backing of resin coating from multiple chambeies.

In another embodiment, the present invention relates to the draft machine equipment of a kind of coated abrasives, comprising:

The tool of production, this tool of production is positioned on the excircle of abrasive grain transferring roller, and this tool of production has distribution surface, and this allocation table mask has multiple chamber；

Web path for the backing of resin coating, this web path guides the backing of resin coating by coated abrasives draft machine equipment, the backing that resin is coated winds a part for the excircle of abrasive grain transferring roller, and wherein the resin bed of the backing of resin coating is towards distribution surface alignment；And

Abrasive grain feeder, abrasive grain is assigned to distribute on surface and in multiple chambeies by it；And

Wherein when the backing that resin coats and the tool of production turn round around abrasive grain transferring roller, abrasive grain is transferred to the backing of resin coating from multiple chambeies.

As used herein; abrasive grain or the chamber with the 3D shape limited by the side of surface relative smooth is referred respectively to about the term " Accurate Shaping " in abrasive grain in support element or chamber; these sides are defined by the sharp edge accurately limited and are engaged, and the length of these sharp edges is different and has by the crossing different end points limited in each side.

As used herein, the abrasive grain only using gravity (although other power, such as, air pressure or vacuum can be used in implementation process) just can remove is referred to from chamber about the term " removable and completely set up in " in chamber.

After considering detailed description of the invention and appended claims, will be further understood that the feature and advantage of the disclosure.

Accompanying drawing explanation

Figure 1A is the schematic diagram of the device for preparing the coated abrasive goods according to the present invention.

Figure 1B is the schematic diagram of another device for preparing the coated abrasive goods according to the present invention.

Fig. 2 is the perspective illustration of the exemplary tool of production 200 according to the present invention.

Fig. 3 A is the amplification diagrammatic top view of example bore 320 design in the chamber 220 being useful as in the tool of production 200.

Fig. 3 B is the sectional view intercepting Fig. 3 A along plane 3B-3B.

Fig. 3 C is the sectional view of Fig. 3 A intercepted along plane 3C-3C.

Fig. 4 A is the amplification diagrammatic top view of example bore 420 design in the chamber 220 being useful as in the tool of production 200.

Fig. 4 B is the schematic sectional view of Fig. 4 A intercepted along plane 4B-4B.

Fig. 4 C is the schematic sectional view of Fig. 4 A intercepted along plane 4C-4C.

Fig. 5 A is the amplification diagrammatic top view of example bore 520 design in the chamber 220 being useful as in the tool of production 200.

Fig. 5 B is the schematic sectional view along the example bore 520 shown in Fig. 5 A of plane 5B-5B intercepting.

Fig. 5 C is the schematic sectional view along the example bore 520 shown in Fig. 5 A of plane 5C-5C intercepting.

Fig. 6 A is the amplification diagrammatic top view of example bore 620 design in the chamber 220 being useful as in the tool of production 200.

Fig. 6 B is the schematic sectional view of Fig. 6 A intercepted along plane 6B-6B.

Fig. 6 C is the schematic sectional view of Fig. 6 A intercepted along plane 6C-6C.

Fig. 7 is the perspective illustration of the exemplary tool of production 700 of an exemplary according to the present invention.

Fig. 8 is the perspective illustration of the exemplary tool of production 800 of an exemplary according to the present invention.

Fig. 9 is the perspective illustration of the exemplary tool of production 900 of an exemplary according to the present invention.

Figure 10 A is the schematic section decomposition diagram of the exemplary perspective view of the abrasive grain alignment system 1000 of an exemplary according to the present invention.

Figure 10 B is the cross-sectional schematic side view of the abrasive grain alignment system 1000 intercepted along plane 10B-10B.

Figure 11 A is the schematic section decomposition diagram of the exemplary perspective view of the abrasive grain alignment system 1100 of an exemplary according to the present invention.

Figure 11 B is the cross-sectional schematic side view of the abrasive grain alignment system 1100 intercepted along plane 11B-11B.

Figure 12 A is the schematic section decomposition diagram of the exemplary perspective view of the abrasive grain alignment system 1200 of an exemplary according to the present invention.

Figure 12 B is the cross-sectional schematic side view of the abrasive grain alignment system 1200 intercepted along plane 12B-12B.

The most reusable reference marks is intended to indicate that the same or similar feature of the disclosure or element.Should be appreciated that those skilled in the art can design other modification of many and embodiment fallen in disclosure concept and essence.Accompanying drawing may not drawn on scale.

Detailed description of the invention

Coated abrasives draft machine equipment

Referring now to Figure 1A and Fig. 2, coated abrasives draft machine equipment 90 according to the present invention includes the abrasive grain 92 being removably disposed in the chamber 220 of the tool of production 200 with the first web path 99, this first web path guides the tool of production to pass through coated abrasives draft machine, so that a part for the excircle of its winding abrasive grain transfer roller 122.This device generally includes, such as, unwind 100, primer layer delivery system 102 and primer layer applicator 104.These parts unwinding backing 106, is delivered to primer layer resin 108 primer layer applicator 104 by primer layer delivery system 102, and applies primer layer resin to the first first type surface 112 of backing.Then, the backing 114 of resin coating is positioned by idler roller 116, so that abrasive grain 92 paint is coated with the first first type surface 112 of primer layer resin 108.The backing that the second web path 132 for the backing 114 of resin coating guides resin to coat passes through coated abrasives draft machine equipment, so that a part for the excircle of its winding abrasive grain transfer roller 122, and resin bed is towards the distribution surface alignment of the tool of production, this tool of production is positioned between backing 114 and the excircle of abrasive grain transfer roller 122 of resin coating.Suitably unwinding, primer layer delivery system, primer layer resin, coating machine and backing are well-known to those skilled in the art.Primer layer delivery system 102 can be the simple dish containing primer layer resin or reservoir, or have storage tank and deliver pipe fitting so that primer layer resin to move to the pumping system of desired location.Backing 106 can be cloth, paper, film, non-woven fabrics, scrim or other web substrates.Primer layer applicator can be such as, coating machine, roller coating machine, paint finishing or rod coating machine.Or, the coating backing of precoating can be positioned by idler roller 116, so that abrasive grain to be applied to the first first type surface.

As mentioned below, the tool of production 200 includes multiple chamber 220, and the plurality of chamber has the shape complementary with the expection abrasive grain wherein comprised.Abrasive grain feeder 118 supplies at least some abrasive grain to the tool of production.Preferably, abrasive grain feeder 118 supplies the abrasive grain of excess, so that the abrasive grain that the tool of production of per unit length exists in the vertical is more more than the chamber existed.In the abrasive grain of supply excess contributes to guaranteeing the tool of production, all chambeies have filled uniformly with abrasive grain.Owing to loaded area and the spacing of abrasive grain are commonly designed in the tool of production and apply for particular abrasive, it is desirable to unfilled chamber is the most too many.Abrasive grain feeder 118 is generally and the tool of production has same widths, and supplies abrasive grain on the width of the whole tool of production.Abrasive grain feeder 118 can be, such as vibration feeder, hopper, skewed slot, silo, drip coating machine or screw feeder.

Optionally, provide to fill after abrasive grain feeder 118 and assist component 120, so that abrasive grain moves back and forth on the surface of the tool of production 200, and help abrasive grain orientation or slide into chamber 220.Filling and assist component 120 can be such as, doctor blade, felt wiper, has the brush of multiple bristle, vibrational system, aerator or air knife, vacuum tank 124 or combinations thereof.Fill the abrasive grain assisting component to move, translate, aspirate or stir on distribution surface 212 (top of the tool of production 200 or upper surface in Figure 1A), so that more abrasive grain is placed in intracavity.If assisting component without filling, the abrasive grain more typically at least dropping down onto distribution surface 212 will fall directly into intracavity, and without the most mobile, but other abrasive grains may need some other movements with in introduction chamber.Optionally, fill and assist the component 120 can teeter, this swing can be across longitudinal direction, or use the suitably driving surface otherwise with the tool of production 200 to have relative motion (such as circular or elliptical motion), to contribute to each chamber 220 being filled up completely with in the tool of production with abrasive grain.Generally, if using brush to assist component as filling, then bristle can cover the part on distribution surface, this part is preferably the longitudinal length of 2-4 inch (5.0 to 10.2cm) on the whole or the most whole width on distribution surface, and lean against gently or only on distribution surface, and there is the motility of appropriateness.If use vacuum tank 125 assists component as filling, then generally combine the tool of production use with the chamber extending fully through the tool of production as shown in Figure 5；Even if but the tool of production with solid back surfaces 314 as shown in Figure 3 is alternatively favourable, because it can flatten and make the tool of production more smooth, thus improving the filling capacity in chamber.Before or after vacuum tank 125 is positioned near abrasive grain feeder 118 and can be positioned abrasive grain feeder, or contain any part of usual netted span between a pair idler roller 116 that abrasive grain filling and the excess of 140 shown devices remove in part.Or, as the replacement of vacuum tank 125 or in addition to this vacuum tank, die shoe or plate supporting or the extrapolation tool of production can be used, to help the tool of production to keep smooth in this part of device.In embodiments, wherein abrasive grain is completely contained in as in the chamber of the tool of production of Figure 11 B, that is in chamber, the major part (such as 80%, 90% or 95%) of abrasive grain does not extend the distribution surface of the tool of production, filling auxiliary part can more easily control make abrasive grain move back and forth on the distribution surface of the tool of production, without evicting from already contained in the single abrasive grain in single chamber.

Optionally, along with the tool of production is towards longitudinal advance, chamber 220 moves to more high altitude and optionally arrives height more higher than the outlet of abrasive grain feeder, and the outlet of this abrasive grain feeder for being assigned to the distribution surface of the tool of production by abrasive grain.If the tool of production is endless belt, then this endless belt is when moving through abrasive grain feeder 118, can proceed to more high altitude obliquely by forward.If the tool of production is roller, then before the top dead-centre of the excircle that abrasive grain feeder 118 can be positioned in roller (on such as roller surface between 270 degree and 350 degree, top dead-centre is 0 degree, when roller is rotated in a clockwise direction at work, top dead-centre is along the traveling clockwise of roller) abrasive grain is applied on roller.It is believed that and be applied to abrasive grain on the inclination distribution surface 212 of the tool of production can allow preferably to fill chamber.Abrasive grain slidably or is rolled on the inclination distribution surface 212 of the tool of production, thus improves and fall into the probability in chamber.In embodiments, wherein abrasive grain is completely contained in as in the chamber of the tool of production of Figure 11 B, that is in chamber, the major part (such as 80%, 90% or 95%) of abrasive grain does not extend the distribution surface of the tool of production, tilt the distribution surface that can also aid in from the tool of production and remove the abrasive grain of excess, because the abrasive grain of excess can skid off the distribution surface of the tool of production towards upstream end.Inclination can be between 0 degree until abrasive grain starts between the angle falling out outside chamber.Preferably tilt will depend upon which abrasive grain shape and abrasive grain is maintained at the size of power (such as friction or vacuum) of intracavity.In some embodiments, forward is tilted in the range of+10 degree to+80 degree, or in the range of+10 degree to+60 degree, or in the range of+10 to+45 degree.

Optionally, it is possible to provide abrasive grain removing components 121 so that all had been filled with abrasive grain once most or all of chamber, contribute to removing excess abrasive grain from the surface of the tool of production 200.Abrasive grain removing components can be the air source such as blown away from the distribution surface of the tool of production by excess abrasive grain, such as air collector, air-shower, air knife, wall attachment effect nozzle or aerator.Contact device can be used as abrasive grain removing components, such as brush, scraper, cleaning piece or doctor blade.The vibrator of such as ultrasonic amplitude transformer can be used as abrasive grain removing components.Or, the vacuum source of such as vacuum tank or vacuum furnace can be used for being retained in chamber abrasive grain, this vacuum tank or vacuum furnace are located in a part for the first web path after abrasive grain feeder 118, and the tool of production has the chamber extending fully through the tool of production, as shown in Figure 5.In this span or part of the first web path, the distribution surface of the tool of production can be squeezed or have the big inclination close to or over 90 degree or decline, to remove excess abrasive grain, method is to utilize gravity to make the abrasive grain of excess from distribution surface landing or drop out, by vacuum, the abrasive grain being arranged in chamber is retained, until distribution surface returns to an orientation to be retained in chamber by abrasive grain under gravity or to be discharged into from chamber by abrasive grain on the backing of resin coating simultaneously.In embodiments, wherein abrasive grain is completely contained in as in the chamber of the tool of production of Figure 11 B, that is in chamber, the major part (such as 80%, 90% or 95%) of abrasive grain does not extend the distribution surface of the tool of production, excess abrasive grain can be made to slide on the whole distribution surface of the tool of production for abrasive grain removing components 121 and landing goes out the tool of production, the abrasive grain being included in chamber without impact.The excessive abrasive grain removed can be collected and return in abrasive grain feeder with recycling.Or, can by with the tool of production by or move towards the direction that the direct of travel of abrasive grain feeder is contrary excess abrasive grain, wherein they can fill the chamber not being occupied.

Leaving generally abrasive grain at device shown in 140 to fill and after excess removes part, the backing 114 that the abrasive grain in the tool of production 220 coats towards resin is advanced.In this part, the height of the tool of production is not particularly important, as long as abrasive grain is retained in chamber, and the tool of production can continue to tilt, decline or level traveling.If the existing abrasive material draft machine of transformation, then the selection positioned generally is determined by the space existed in machine.Provide abrasive grain transferring roller 122, and the tool of production 220 is commonly wrapped about at least some of of roller excircle.In some embodiments, the tool of production is wound between 30 degree to 180 degree of the excircle of abrasive grain transferring roller, or between 90 degree to 180 degree.The backing 114 of resin coating generally goes back at least some of of take-up roll circumference; make when backing and the tool of production of resin coating turn round around abrasive grain transferring roller 122; and the tool of production 220 is located between backing and the outer surface of abrasive grain transferring roller of resin coating; and the distribution surface of the tool of production towards and during resinous coat first first type surface of usual alignment backing, the abrasive grain in chamber is transferred on the backing of resin coating from chamber.Compared to the tool of production, the backing of resin coating is commonly wrapped about the least part of abrasive grain transferring roller.In some embodiments, the backing of resin coating is wound between 40 degree to 170 degree of the excircle of abrasive grain transferring roller, or between 90 degree to 170 degree.Preferably, the speed of the resin bed of the backing of the distribution speed on surface and resin coating be such as ± 10%, ± 5% or ± 1% in the speed that matches each other.

Can use various method that abrasive grain is transferred to from the chamber of the tool of production backing of resin coating.Described various method has (All names are arranged in random order):

1. gravity auxiliary, wherein the tool of production and distribution surface are squeezed in its part being longitudinally travelled, and abrasive grain drops on the backing of resin coating under gravity from chamber.The most in the method, the tool of production has the lateral edge portions of two band foot member 260 (Fig. 2), described foot member is positioned on distribution surface 212 and the backing that (do not applies resin) on two relative limits of backing and coat with resin contacts, so that when the backing that resin coats and the tool of production are wound on abrasive grain transferring roller, resin bed is maintained at the distribution surface of the tool of production just above.Therefore, there is gap, to avoid any resin to be transferred on the distribution surface of the tool of production between the top surface of the resin bed on the backing of distribution surface and resin coating.In one embodiment, the backing of resin coating has two sidebands the most resiniferous and resinous coat mid portion, and distributes surface and can have two protruding arch ribs, described arch rib at the longitudinal extension of the tool of production to contact with the most resiniferous limit of backing.In another embodiment, abrasive grain transferring roller can have two protruding arch ribs or ring in the either end of roller, and there is the mid portion of small diameter, and when the tool of production is wound on abrasive grain transferring roller, in the mid portion of the small diameter that the tool of production is included in abrasive grain transferring roller.The resin bed of the backing that resin is coated by arch rib protruding on abrasive grain transferring roller or end ring is increased to distribute the top on surface so that the two exists gap between surface.Or, the protruding pillar being distributed on tool of production surface can be used for keeping the gap between the two surface.Or, can be applied to the existing application of (the biggest) granule maintain on the resinous coat in the gap between the backing of resin coating and distribution surface.In still another embodiment, distribution surface can be spaced apart with the backing of resin coating, thus keeps gap between the backing of distribution surface and resin coating, and any contact does not occur.

2. extrapolation auxiliary, wherein each chamber in the tool of production has two openings so that abrasive grain can be located in chamber, and a part for abrasive grain extends the back surfaces 214 of the tool of production.Under extrapolation auxiliary, the tool of production is no longer necessary to be squeezed, but still can be squeezed.When the tool of production is wound on abrasive grain transferring roller, the outer surface of roller engages with the abrasive grain in each chamber and is released by abrasive grain outside chamber, advances in the resin bed on the backing of resin coating.In some embodiments, the outer surface of abrasive grain transferring roller includes having the resiliency compressible layer being measured as such as 20 to 70 Durometer A hardness by durometer, applies this resiliency compressible layer to provide additional compliance when the backing of abrasive grain propelling resin coating.In another embodiment of extrapolation auxiliary, as the replacement or in addition of the elastic outer layer of abrasive grain transferring roller, the back surfaces of the tool of production can cover with resiliency compressible layer, as illustrated in fig. 12.

3. vibration auxiliary, wherein by suitable source vibration abrasive grain transferring roller or the tool of production of such as Vltrasonic device, abrasive grain to shake out chamber and arrives on the backing of resin coating.

4. pressure auxiliary, wherein each chamber in the tool of production has two openings (Fig. 3), or back surfaces 314 or the whole tool of production are porous suitably, and abrasive grain transferring roller has multiple hole and internal air pressure source.Under pressure assists, the tool of production is no longer necessary to be squeezed, but still can be squeezed.Abrasive grain transferring roller also can have moveable internal insulation wall so that forced air can be provided to specific arc section or the excircle of roller, with on the backing that abrasive grain is blown out chamber and arrives resin coating by ad-hoc location.In some embodiments, abrasive grain transferring roller may also be provided as having inner vacuum source, described inner vacuum source without corresponding pressure span or is combined with pressure span, and described inner vacuum source is when abrasive grain transferring roller rotates, generally before pressure span.Vacuum source or region can have moveable dividing wall, to direct it to specific region or the arc section of abrasive grain transferring roller.When abrasive grain is before standing the pressure span of abrasive grain transferring roller, and the tool of production is wound on abrasive grain transferring roller, and abrasive grain can firmly be inhaled in chamber by vacuum.This vacuum area such as with abrasive grain removing components with the use of, to remove excess abrasive grain from distribution surface, maybe can be simply used for guaranteeing abrasive grain arrive along before the ad-hoc location of the excircle of abrasive grain transferring roller without departing from chamber.

Multiple embodiment the most listed above is not defined in and is used independently, can mixed on demand and coupling they with more effectively abrasive grain is transferred to from chamber resin coating backing.

Each abrasive grain is accurately shifted and is positioned on the backing of resin coating by abrasive grain transferring roller 122, substantially replicates the abrasive grain pattern as being arranged in the tool of production and specific orientation thereof.Therefore, coated abrasives can produce with the speed of 5 feet/min-15 feet/min (1.5 ms/min-4.6 ms/min) or more speed first, and the most each abrasive grain is placed on the accurate location on the backing of resin coating and/or radial oriented available accurately control！As shown in embodiment afterwards, abrasive grain weight identical in the abrasive material of coated abrasives can realize the grinding performance more significantly higher than the electrostatic deposition process of prior art.

After separating with abrasive grain transferring roller 122, if it is desired, with the help of idler roller 116, the tool of production is filled and excess removes part along the first web path 99 generally abrasive grain at 140 shown devices of advancing back.Optional tool of production cleaner 128 can be provided to remove the jammed abrasive grain being still located in chamber and/or to remove the primer layer resin 108 being transferred to distribute surface 212.The selection of tool of production cleaner will depend upon which the structure of the tool of production, and can be extra air stream, solvent or water spray, solvent or water-bath, ultrasonic amplitude transformer or the idler roller of separately or combined formula, the tool of production winds this idler roller to use extrapolation auxiliary to force abrasive grain to arrive outside chamber.Then, the annular tool of production 220 or tape travel are filled to abrasive grain and excess removes part 140, to be received in new abrasive grain.

Multiple idler roller 116 can be used to guide abrasive grain coating backing 123, described abrasive grain coating backing has predetermined, the reproducible non-random pattern of abrasive grain at the first first type surface, described abrasive grain is applied on the first first type surface by abrasive grain transferring roller, and enters baking oven 124 along the second web path 132 keep on the first major surface through primer layer resin with cured base Subbing resins.Optionally, it is possible to provide the second abrasive grain coating machine 126, extra abrasive grain (such as another kind of abrasive grain or diluent) is placed on primer layer resin before entering baking oven 124.Second abrasive grain coating machine 126 can be drip coating machine known to those skilled in the art, Bracewell coater or electrostatic applications machine.Then, cured backing 128 with abrasive grain can enter optional suspension basket 130 along the second web path before further processing, described in be further processed as such as adding re-glue, solidify re-glue and known to the skilled person other of preparing in coated abrasives field process steps.

Referring now to Figure 1B and Fig. 2, include the abrasive grain 92 being removably disposed in the forming cavity 220 of the tool of production 200 according to another device 90 of the present invention.In this embodiment, the tool of production can be the sleeve pipe being fitted on abrasive grain transferring roller 122, or chamber 220 can be by the excircle being machined directly into abrasive grain transferring roller 122.Unwinding and primer layer delivery system not shown in Figure 1B.Primer layer resin 108 is applied on the first first type surface 112 of backing 106 by coating machine 104, forms the backing 114 of resin coating.Then, the backing 114 that resin coats is directed to wind a part for the top dead-centre (TDC) 115 passing through abrasive grain transferring roller 122 on the excircle of abrasive grain transferring roller by a pair idler roller 116.As it was noted above, abrasive grain 92 is applied on abrasive grain transferring roller 122 before tdc by abrasive grain feeder 118, and it is preferably applied the abrasive grain of excess.In some embodiments, the backing 114 of resin coating is wound between 20 degree to 180 degree of the excircle of abrasive grain transferring roller 122, or between 20 degree to 90 degree.

The abrasive grain holding member 117 of optional such as plate or skewed slot can be placed on the distribution surface 212 of the neighbouring tool of production, place before tdc, is supplied to the abrasive grain on distribution surface freely to drop to stop by abrasive grain feeder 118.The gradient of scalable abrasive grain holding member or inclination, to maintain abrasive grain supply to deposit in chamber on or near distribution surface, and excess abrasive grain from inclined surface landing and enters tray 119.As the first embodiment, optional filling auxiliary part 120 and optional abrasive grain removing components 121 also can be used in the present embodiment.Optional vacuum tank 125 can be used, to be drawn in chamber by abrasive grain inside abrasive grain transferring roller.Once abrasive grain is transferred to the backing 114 of resin coating and after abrasive grain coating backing 123 is directed to leave abrasive grain transferring roller 122, can perform all as described above for the further process described in the first embodiment.

The preparation method of coated abrasives

Coated abrasives draft machine equipment is generally shown in Figure 1A.The invention provides a kind of method, described method relates generally to use single abrasive grain to fill the step in each described chamber in the tool of production.The backing that the tool of production of filling coats with resin is alignd, described abrasive grain to be transferred to the backing of described resin coating.Described abrasive grain is transferred to from described chamber on the backing of described resin coating, and the described aligned position of the backing coated from described resin by the described tool of production removes.Then solidify described resin bed, apply complex layer and solidify, and by suitable conversion equipment, described coated abrasives being converted into thin plate, dish or band forms.

In other embodiments, can use discontinuous method, wherein the tool of production of a segment length can be received in abrasive grain, the backing location being aligned in or coating with the resin of a segment length, making the distribution surface of the resin bed facing to manufacture instrument of backing, then abrasive grain is transferred to resin bed from chamber.Can manually or use robot type equipment be automatically brought into operation discontinuous method.

In a specific embodiment, a kind of method preparing patterned abrasive layer on the backing of resin coating, comprise the following steps.Not necessarily perform these steps that performs in steps or in order, but these steps can be performed in the sequence listed or perform additional step between two steps.

One step can be to provide the tool of production (Figure 11 B) on a kind of distribution surface 1112 with band chamber 320, and each chamber has the longitudinal cavity axis 247 being perpendicular to distribute surface, and degree of depth D260 along longitudinal cavity axis.The chapters and sections of the entitled tool of production and abrasive grain alignment system disclose other information about the useful tool of production and chamber.

Another step can be to select elongated abrasive grain, and described abrasive grain has length L270 along granule longitudinal axis, along being perpendicular to the width W of axis of pitch of granule longitudinal axis, and length L is more than width W.Elongated abrasive grain can be disclosed herein any with reference to abrasive grain.Longitudinal granule axis is to be aligned in and be parallel to the maximum sized axle of abrasive grain.For rod abrasive grain, longitudinal granule axis location is in the center of cylindrical abrasive grain length.For equilateral triangle abrasive grain, longitudinal granule axis intersects with a summit of triangle, and at right angles intersects with opposite side, and is arranged on equably between equilateral triangle opposite face.

In selected embodiment, degree of depth D260 in chamber is between 0.5 times of L (0.5L) and 2 times of L (2L), or between 1.1 times of L (1.1L) and 1.5 times of L (1.5L), the elongated abrasive grain being arranged in chamber is positioned in the subsurface tool of production of distribution, as shown in Figure 11 B.In another embodiment, when in the fully-inserted chamber of abrasive grain, the mass centre of abrasive grain is positioned in the chamber of the tool of production.As the degree of depth of fruit caving becomes too short, and the mass centre of abrasive grain is located in outside chamber, then abrasive grain is not easy to be retained in chamber, and when the tool of production is translated across device, abrasive grain can be jumped out outside the tool of production.In a preferred embodiment, elongated abrasive grain is arranged and allows excess abrasive grain to slide around distribution surface under the surface, to be moved into chamber or to remove from distribution surface.

Another step can be the elongated abrasive grain to distribution surface supply excess so that the elongated abrasive grain of offer is more more than the number in chamber.The elongated abrasive grain of excess refers to present in the tool of production of per unit length that elongated abrasive grain is more more than present in chamber, during to contribute to guaranteeing that they are moved in chamber by the power piling up on distribution surface when elongated abrasive grain and applying due to gravity or other machinery, all chambeies in the tool of production are finally received in abrasive grain.Owing to loaded area and the spacing of abrasive grain are commonly designed in the tool of production and apply for particular abrasive, it is desirable to unfilled chamber is the most too many.

Another step can be to fill the most of chambeies in distribution surface with elongated abrasive grain, and this elongated abrasive grain is arranged in single chamber so that longitudinal granule axis of elongated abrasive grain is parallel to longitudinal cavity axis.Wish to be transferred to by elongated abrasive grain on the backing of resin coating so that they erect or are erectly applied.Therefore chamber shape is designed to erectly keep elongated particle.In various embodiments, at least the 60% of chamber, 70%, 80%, 90% or 95% in distribution surface comprises elongated abrasive grain.In some embodiments, gravity can be used to fill chamber.In other embodiments, the tool of production can be squeezed and be applied in vacuum, abrasive grain or elongated abrasive grain to be maintained in chamber.Abrasive grain can be applied by spraying, fluid bed (air or vibration) or electrostatic applications.Can removing, because any unreserved abrasive grain will down drop by gravity realization excess abrasive grain.Then, by removing vacuum, abrasive grain can be transferred to the backing of resin coating.

Another step can be after filling step, removes the remainder of the elongated abrasive grain of the excess being not disposed in chamber from distribution surface.As depicted, supplying than chamber more elongated abrasive grain, in order to after each chamber is filled, some elongated abrasive grains will be retained on distribution surface.The elongated abrasive grain of these excess generally can be blown away, wipes out or otherwise be removed from distribution surface.Such as, vacuum or other power can be applied to be maintained in chamber by elongated abrasive grain, and distribution surface is inverted, to remove the remainder of the elongated abrasive grain of excess on distribution surface.

Another step can be the backing and distribution surface in alignment coated by resin, makes resin bed towards distribution surface.Various method aligned surfaces can be used, as shown in FIG. 1A and 1B, or manually or robot uses backing and the tool of production of the discontinuous length location resin coating of each in the backing of resin coating and the tool of production.

Another step can be that the elongated abrasive grain in chamber is transferred to the backing of resin coating, and elongated abrasive grain is attached to resin bed.Transfer can use gravity to assist, and wherein said distribution surface is oriented to allow gravity to make elongated abrasive grain landing in chamber in filling step, and distributes surface and is squeezed in transfer step, to allow gravity to make elongated abrasive grain landing go out chamber.Transfer can use extrapolation auxiliary, and wherein elongated abrasive grain can laterally be moved to contact with resin bed by contact member (excircle of such as abrasive grain transferring roller, the optional compressible elastomeric layer attaching to tool of production carrier layer back surfaces or the another kind of device of such as doctor blade or cleaning piece) along longitudinal cavity axis.Transfer can use pressure to assist, and wherein air blows into chamber from the opening on distribution surface, especially has the chamber of opening opposite end, laterally to be moved along longitudinal cavity axis by elongated abrasive grain.Transfer can use vibration auxiliary, by the vibration tool of production so that elongated abrasive grain is shaken out chamber.These various methods may be used alone or in combination use.

Another step can be to remove the tool of production, to expose the patterned abrasive layer on the backing of resin coating.Can use multiple removing or separation method, as shown in Figure 1A and 1B, or manually the backing that the tool of production coats with resin be separated and lift the tool of production.Patterned abrasive layer is a series of elongated abrasive grains, and this elongated abrasive grain has the most repeatably pattern, is coated with, with electrostatic applications or drip, the random distribution created contrary.

In any one of the embodiment above, elongated abrasive grain can be moved around after supply step on distribution surface by previously described filling auxiliary part, to guide elongated abrasive grain to enter in chamber.In any one of foregoing embodiments, chamber, when the longitudinal cavity axis in edge, distribution surface moves, can be inwardly tapered.In any one of foregoing embodiments, chamber can have the chamber circumferential periphery around longitudinal cavity axis, and elongated abrasive grain has an abrasive grain circumferential periphery around longitudinal granule axis, and the form fit of the shape of chamber circumferential periphery and elongated abrasive grain circumferential periphery.In any one of foregoing embodiments, elongated abrasive grain can be equilateral triangle, and the width along granule longitudinal axis of elongated abrasive grain is nominally identical.The Nominal Width of elongated abrasive grain refers to that the change of width dimensions is less than ± 30%.

The tool of production and abrasive grain alignment system

Abrasive grain alignment system according to the present invention includes the abrasive grain being removably disposed in the forming cavity of the tool of production.

Referring now to Fig. 2, the exemplary tool of production 200 includes having distribution surface 212 and the support element 210 of back surfaces 214.Distribution surface 212 includes chamber 220, and this chamber chamber opening 230 from distribution surface 212 extends into support element 210.Optional compressible elastomeric layer 240 is fixed in back surfaces 214.Chamber 220 is arranged in array 250, and array is arranged to have the main shaft 252 in offset angle of the longitudinal axis 202 (in this example or band or roller, corresponding to longitudinally) relative to the tool of production 200.

Generally, the opening in the chamber on the distribution surface of support element is rectangle；But this is not necessarily.The length of support element lumen, width and the degree of depth depend on typically at least in part they by with the use of the shape and size of abrasive grain.Such as, if abrasive grain be shaped as equilateral triangle plate, if that abrasive grain will be comprised in chamber, the length in the most single chamber should be preferably 1.1 times to 1.2 times of the greatest length of the side of abrasive grain, the width in single chamber is preferably 1.1 times to 2.5 times of abrasive grain thickness, and the respective depth in chamber should be preferably 1.0 times to 1.2 times of abrasive grain width.

Or, such as, if abrasive grain be shaped as equilateral triangle plate, then if abrasive grain will highlight from chamber, the length in the most single chamber should be less than abrasive grain, and/or the respective depth in chamber should be less than the width of abrasive grain.Similarly, the width in reply chamber should select so that single abrasive grain is fitted in each chamber.

Similarly, the width in reply chamber should select so that single abrasive grain is fitted in each chamber.

Optional machine-direction oriented foot member 260 arranges (such as using binding agent or other modes) along the relative limit on distribution surface 212.The design variant form of foot member height allow regulation chamber opening 230 and and the substrate (such as there is on it backing of primer layer precursor) that comes in contact of the tool of production between distance.

If it does, machine-direction oriented foot member 260 can have any height, width and/or spacing (preferably they have about 0.1mm to the height of about 1mm, about 1mm to the width of about 50mm and the spacing of about 7mm to about 24mm).Single machine-direction oriented foot member can be such as continuous print (such as arch rib) or discontinuous (arch rib of such as segmentation or pillaring).Include that in the case of coiled material or band, machine-direction oriented foot member is generally parallel to the longitudinal direction at the tool of production.

The function of offset angle is to be arranged on final coated abrasives with the pattern that will not produce groove within the workpiece by abrasive grain.Offset angle can have the arbitrary value of 0 degree to about 30 degree, but preferably in the range of 1 degree to 5 degree, more preferably in the range of 1 degree to 3 degree.

Suitably support element can be rigidity or flexibility, but the most sufficiently flexible, to allow to use conventional Web-processing apparatus, such as roller.Preferably, support element includes metal and/or organic polymer.These organic polymers are the most moldable, have low cost and the most durable when for the abrasive grain depositing operation of the present invention.Can be thermosetting and/or thermoplasticity, the example that may be adapted to manufacture the organic polymer of support element includes: polypropylene, polyethylene, vulcanite, Merlon, polyamide, nitrile-butadiene-styrene plastics (ABS), polyethylene terephthalate (PET), polybutylene terephthalate (PET), polyimides, polyether-ether-ketone (PEEK), polyether-ketone (PEK), and acetal plastic (POM, acetal), poly-(ether sulfone), poly-(methyl methacrylate), polyurethane, polrvinyl chloride and combinations thereof.

The tool of production can be following form, such as endless belt (such as, endless belt 200 as shown in Figure 1A), thin plate, continuous print thin plate or coiled material, applicator roll, the sleeve pipe being arranged on applicator roll or mould.If the tool of production is band, thin plate, coiled material or barrel forms, then it will have contact surface and non-planar contact surfaces.If the tool of production is roll form, then it will only have contact surface.The surface character of the abrasive grain formed by this method will have the reverse of the pattern of the contact surface of the tool of production.The pattern of the contact surface of the tool of production be generally characterised in that multiple hole or recess.The opening in these chambeies can have any shape, rule or irregular, such as rectangle, semicircle, circle, triangle, square, hexagon or octagon.The wall in chamber can be vertical or taper.The pattern formed by chamber can arrange can be maybe random according to specific plan.Advantageously, chamber can flush each other.

Support element can such as be made according to following procedure.First master tool is provided.Master tool is generally made up of metal such as nickel.Master tool can use any conventional technique to be processed, all such as (e.g.) engraving, gear hobbing, embossing, electroforming, diamond turning or Laser Processing.Be it desired on tool of production surface have pattern, then master mold should have the pattern contrary with tool of production surface.Thermoplastic can use master tool to imprint to form pattern.Impressing can be carried out under thermoplastic is in flowable state.After impressing, can be by thermoplastic hardening by cooling.

Also by imprint patterns being formed on the polymeric film of softening that formed, heated support element.In this case, film thickness is smaller than the chamber degree of depth.This is favourable for improving the flexibility of the carrier with deep chamber.

Support element also can be made up of the thermosetting resin solidifying.The tool of production can being made up of thermosets according to following process manufacture.Uncured thermosets is applied to the master tool of the above-mentioned type.When uncured resin is on master tool surface, can be by being heating and curing or polymerization resin so that hardening of resin becomes to have the shape contrary with master tool picture on surface.Then, from the thermosetting resin of master tool surface removal solidification.The tool of production can be made up of the radiation-hardenable resins solidifying, such as acrylated urethane oligomers.The manufacture of the tool of production of radiation curing is identical with the tool of production being made up of thermosetting resin, and except for the difference that solidification is to carry out by the way of being exposed to radiation (such as ultraviolet radiation).

Support element can have any thickness, as long as support element has enough degree of depth to accommodate abrasive grain and enough flexibilities and ruggedness to use in a manufacturing process.If support element includes endless belt, the support element thickness of the most about 0.5 millimeter to about 10 millimeter is typically available；But this is not necessarily.

Chamber can have any shape, and selects generally according to application-specific.Preferably, at least some of (and it is highly preferred that most of or whole) in chamber is to shape (the most independently, be intentionally designed to be have given shape and size), and more preferably Accurate Shaping.In some embodiments, chamber has the smooth wall and sharp-pointed angle formed by molding process, and has the surface character contrary with master tool (such as diamond turning master metal tool roller), is formed by contacting with master tool.Chamber can be (i.e. the having the bottom of closing) closed.

Preferably, at least some sidewall starts to be inwardly tapered from respective chamber opening, on the distribution surface of the support element that this chamber opening is positioned at the chamber degree of depth with increase, or is positioned in back surfaces.It is highly preferred that all sidewalls start to be inwardly tapered from opening, on the distribution surface of the support element that this opening is positioned at the chamber degree of depth (i.e. having the distance away from distribution surface of increase) with increase.

In some embodiments, at least some chamber includes the first side wall, the second sidewall, the 3rd sidewall and the 4th sidewall.In some embodiments, the first side wall, the second sidewall, the 3rd sidewall and the 4th sidewall can be continuous print and be connected.

In embodiments, its lumen does not have lower surface and does not extends to back surfaces by support element, and the first wall and the 3rd wall can intersect at straight line, and the second sidewall and the 4th sidewall do not contact each other.

Fig. 3 A-3C shows an embodiment in this type of chamber.Referring now to Fig. 3 A-3C, the example bore 320 in support element 310 has length 301 and width 302 (seeing Fig. 3 A) and the degree of depth 303 (seeing Fig. 3 B).Chamber 320 includes four sidewall 311a, 311b, 313a, 313b.Sidewall 311a, the 311b opening 330 from the distribution surface 312 of support element 310 extends and with cone angle beta inwardly along with the degree of depth increases tapered, until they cross at straight line 318 (seeing Fig. 3 B).Equally, sidewall 313a, 313b increase tapered along with the degree of depth with cone angle gamma inwardly, until they contacts straight line 318 (seeing Fig. 3 A and 3C).

Cone angle beta and γ will generally depend on select for the tool of production with the use of specific abrasive grain, preferably correspond to the shape of abrasive grain.In this embodiment, cone angle beta may be greater than 0 degree and is less than any angle of 90 degree.In some embodiments, the value of cone angle beta is in the range of 40 degree to 80 degree, preferably in the range of 50 degree to 70 degree, and more preferably in the range of 55 degree to 65 degree.Equally, cone angle gamma generally depends on general selected.In this embodiment, any angle in the range of cone angle gamma can be 0 degree to 30 degree.In some embodiments, the value of cone angle gamma is in the range of 5 degree to 20 degree, preferably in the range of 5 degree to 15 degree, and more preferably in the range of 8 degree to 12 degree.

In some embodiments, distribution surface and the back surfaces in chamber is opening.In some of such embodiment, the first side wall and the 3rd sidewall do not contact each other and the second sidewall and the 4th sidewall do not contact each other.

Fig. 4 A to 4B shows the alternative cavity 420 of similar type.Referring now to Fig. 4 A-4C, the example bore 420 in support element 410 has length 401 and width 402 (seeing Fig. 4 A) and the degree of depth 403 (seeing Fig. 4 B).Chamber 420 includes four inclined-plane 460a, 460b, 462a, 462b contacted with the distribution surface 412 of support element 410, and four corresponding sidewall 411a, 411b, 413a, 413b.Inclined-plane 460a, each in 460b, 462a, 462b is the most tapered with cone angle δ (seeing Fig. 4 B), and contributes to being directed in chamber 420 abrasive grain.Sidewall 411a, 411b extend from inclined-plane 460a, 460b and with cone angle ε inwardly along with the degree of depth increases tapered, until they cross at straight line 418 (seeing Fig. 4 B).Equally, sidewall 413a, 413b increase tapered along with the degree of depth with cone angle ζ inwardly, until they contacts straight line 418 (seeing Fig. 4 B and Fig. 4 C).

Cone angle δ will generally depend on select for the tool of production with the use of specific abrasive grain, preferably correspond to the shape of abrasive grain.In this embodiment, cone angle δ may be greater than 0 degree and is less than any angle of 90 degree.Preferably, the value of cone angle δ is in the range of 20 degree to 80 degree, preferably in the range of 30 degree to 60 degree, and more preferably in the range of 35 degree to 55 degree.

Cone angle ε will generally depend on select for the tool of production with the use of specific abrasive grain.In this embodiment, cone angle ε may be greater than 0 degree and is less than any angle of 90 degree.In some embodiments, the value of cone angle ε is in the range of 40 degree to 80 degree, preferably in the range of 50 degree to 70 degree, and more preferably in the range of 55 degree to 65 degree.

Cone angle ε by generally depend on equally select be used for the tool of production with the use of specific abrasive grain.In this embodiment, any angle in the range of cone angle ζ can be 0 degree to 30 degree.In some embodiments, the value of cone angle ζ is in the range of 5 degree to 25 degree, preferably in the range of 5 degree to 20 degree, and more preferably in the range of 10 degree to 20 degree.

Chamber can have the second opening in back surfaces.In this case, the second opening is preferably less than the first opening so that abrasive grain is the most completely by two openings (the i.e. second opening is sufficiently small, to avoid abrasive grain to pass through support element).

Fig. 5 A-5C shows an exemplary in this type of chamber.Referring now to Fig. 5 A-5C, the example bore 520 in support element 510 has length 501 and width 502 (seeing Fig. 5 A) and the degree of depth 503 (seeing Fig. 5 B).Chamber 520 includes four sidewall 511a, 511b, 513a, 513b.Sidewall 511a, 511b opening 530 from the distribution surface 512 of support element 510 extends and with cone angle η inwardly along with the degree of depth increases tapered, until they contact conduits 565, this conduit extends to the second opening 570 (seeing Fig. 5 B) in the back surfaces 514 of support element 510.Equally, sidewall 513a, 513b increase tapered, until they contact the second opening 570 (seeing Fig. 5 C) along with the degree of depth with taper angle theta inwardly.Conduit 565 is shown with constant section；But this is not necessarily.

Cone angle η and θ will generally depend on select for the tool of production with the use of specific abrasive grain, preferably correspond to the shape of abrasive grain.In this embodiment, cone angle η may be greater than 0 degree and is less than any angle of 90 degree.In some embodiments, the value of cone angle η is in the range of 40 degree to 80 degree, preferably in the range of 50 degree to 70 degree, and more preferably in the range of 55 degree to 65 degree.

Equally, taper angle theta generally depends on general selected.In this embodiment, any angle in the range of taper angle theta can be 0 degree to 30 degree.In some embodiments, the value of cone angle gamma is in the range of 5 degree to 25 degree, preferably in the range of 5 degree to 20 degree, and more preferably in the range of 10 degree to 20 degree.

Fig. 6 A-6C shows another embodiment in the chamber on the distribution surface and back surfaces of support element with opening.Referring now to Fig. 6 A-6C, support element 610 includes aliging with the compressible conduit 621 in resiliency compressible layer 640 in the chamber 620 in support element 610, this support element.The compressible conduit 621 second opening 670 from the back surfaces 614 of support element 610 extends through resiliency compressible layer 640.Though it is shown that compressible conduit, but it will be appreciated that it be also possible to use the compressible chamber structure of closing.

According at least one pattern positioning chamber following: predetermined pattern, the pattern such as alignd (such as array), circular pattern, irregular but the pattern of section aligned or pseudo-random pattern.

Preferably, length and/or the width in chamber increase along with the chamber degree of depth and narrow, and the chamber opening part on distribution surface is maximum.Chamber size and/or shape is preferably chosen to the given shape with abrasive grain and/or dimensional fits uses.Chamber can include the combination of such as difformity and/or size.Chamber size enough should accommodate at least in part at intracavity and be orientated single abrasive grain.In some embodiments, being largely or entirely retained in chamber of abrasive grain so that the opening extending through chamber residing for abrasive grain less than about 20% (more preferably less than 10% or even less than 5%) of abrasive grain length.In some embodiments, being largely or entirely fully located in (being i.e. fully retained in) chamber of abrasive grain, and do not extend across the abrasive grain corresponding chamber opening on the distribution surface of support element.

In some embodiments, chamber can be cylindrical or taper.If using the abrasive particle pulverized or the granule (such as diamond) of octahedra shape, then this point is especially needed.

Chamber includes at least one sidewall and can include at least one lower surface；It is preferable, however, that whole chamber shape is by any limited opening in sidewall and distribution surface and back surfaces.In some preferred embodiments, chamber has at least 3, at least 4, at least 5, at least 6, at least 7, at least 8 sidewalls.

Sidewall is preferably smooth, but this is not necessarily.Such as, sidewall can be plane, arc (such as concave surface or convex surface), taper or conical butt.

In some embodiments, first surface and the back surfaces in chamber is opening.In some of such embodiment, the first side wall and the 3rd sidewall do not contact each other and the second sidewall and the 4th sidewall do not contact each other.

In some embodiments, in sidewall at least one, at least two, at least 3 or even at least 4 be convex surface.

In some embodiments, at least some chamber can include one or more inclined-plane being arranged between distribution surface and any or all sidewall independently.This inclined-plane can be conducive to abrasive grain in the setting of intracavity.

For avoiding primer layer precursor resin to pile up on the distribution surface of support element, at least two foot member that longitudinally (being i.e. oriented to be arranged essentially parallel to the longitudinal direction of used carrier component/tool of production) is protruding is preferably fixed to carrier or is integrally formed with carrier.Preferably, at least two in foot member is arranged to adjacent with the side along tool of production length.The example of the suitable foot member can being integrally formed with support element includes pillar and arch rib (continuous print or segmentation).The orientation of the machine-direction oriented foot member by single elongated raised (such as arch rib or band) of foot member realizes, or is realized by the pattern in low ring footpath raised feet component (such as isolating row) or other pillar patterns or other protruding features.

Referring now to Fig. 7, an exemplary tool of production 700, endless belt includes the support element 710 with chamber 720.Machine-direction oriented raised feet component 742,744 are made up of continuous print arch rib, this arch rib along and be adjacent to the side 732 of support element 700,734 are integrally formed, thus provide skew between the backing of the distribution surface 712 of support element 710 and the coating of primer layer precursor during transfer abrasive grain.The most machine-direction oriented raised feet component 746,748 is made up of arch rib, and this arch rib is integrally formed at the spacing of whole support element 710 width.

Alternatively or additionally, foot member can additionally be fixed to support element；Such as use binding agent or machanical fastener.A preferably example of foot member includes with adhesive-backed band.Such as, band can be applied only to the distribution surface of support element, or can fold and adhere to the back surfaces of support element at the side of support element.Referring now to Fig. 8, an exemplary tool of production 800, endless belt includes the support element 810 with chamber 820.Band 842,844 are applied in the side 832 of support element 800, around 834, thus provide skew between the backing of the distribution surface 812 of support element 810 and the coating of primer layer precursor during transfer abrasive grain.

Alternatively or additionally, multiple foot member (such as multirow projection pillar) by be positioned at along be adjacent at the spacing of support element side come jointly towards machine-direction oriented.Referring now to Fig. 9, an exemplary tool of production 900, endless belt includes the support element 910 with chamber 920.Multirow projection pillar 942,944 is adjacent to the side 932,934 of support element 910 in support element 910 and is integrally formed, thus provides skew between the backing of the distribution surface 912 of support element 910 and the coating of primer layer precursor during transfer abrasive grain.

Alternatively or additionally, gap can be kept between the tool of production and coated substrate, to prevent any contact between the two surface.

Support element and the design of master tool used in their manufacture and manufacture be found in such as United States Patent (USP) 5,152,917 (Pieper et al.), 5,435,816 (Spurgeon et al.), 5,672,097 (Hoopman et al.), 5,946,991 (Hoopman et al.), 5,975,987 (Hoopman et al.), with 6,129,540 (Hoopman et al.).

For forming abrasive grain alignment system, as described herein, abrasive grain is fed at least some chamber of support element.

Abrasive grain can use any suitable technology to be arranged in the chamber of support element.These examples include, when when being oriented to distribute surface towards top of support element, being rendered to by abrasive grain on support element, and then shake well granule is so that they fall in chamber.The suitably example of shaking method can include brushing, blows, vibrates, apply vacuum (having the support element of opening for microcavity back surfaces) and combinations thereof.

In typical use, abrasive grain is removably disposed in the tool of production at least one of chamber, in the chamber of preferably at least 50%, 60%, 70%, 80%, 90% or even 100%.Preferably, abrasive grain removedly and is disposed entirely within least some chamber, it is highly preferred that abrasive grain removedly and is disposed entirely within the chamber of at least 80%.In some embodiments, abrasive grain is outstanding or be entirely in chamber from chamber, or combinations thereof.

Such as, referring now to Figure 10 A and Figure 10 B, abrasive grain alignment system 1000 includes abrasive grain 1080 and the tool of production 1005.Abrasive grain 1080 is partially disposed in the chamber 320 (as shown in figs. 3 a-3 c) on distribution surface 1012 of the support element 1010 of the tool of production 1005.In this embodiment, abrasive grain 1080 is outstanding from respective chamber 320.

Referring now to Figure 11 A and Figure 11 B, abrasive grain alignment system 1100 includes abrasive grain 1180 and the tool of production 1105.Abrasive grain 1180 is disposed entirely within the chamber 320 (as shown in figs. 3 a-3 c) on distribution surface 1112 of the support element 1110 of the tool of production 1105.

Referring now to Figure 12 A and Figure 12 B, abrasive grain alignment system 1200 includes abrasive grain 1280 and the tool of production 1205.Abrasive grain 1280 is partially disposed in the chamber 620 (as shown in figs 6 a-6 c) on distribution surface 12112 of the support element 1210 of the tool of production 1205.In this embodiment, abrasive grain 1280 is partially disposed in respective chamber 620, and tip projects to compressible conduit 621.Elasticity of compression compressible stratum 640 (being such as pressed on roller) makes abrasive grain extrude from chamber.

As discussed above, resiliency compressible layer can be fixed to the back surfaces of support element, and no matter whether chamber extends to back surfaces.This can be conducive to web process and/or remove abrasive grain from chamber.Such as, in embodiments, wherein resiliency compressible layer includes profiled recess, at least some of in this recess respectively orientation alignment chamber in each the second opening, can be by applying pressure to resiliency compressible layer, the abrasive grain that will extend in the chamber of profiled recess is mechanically extruded from chamber.Such as, this can realize by compressing on nip rolls, and wherein in the manufacture process of coated abrasives, abrasive grain alignment system contacts on backing with primer layer precursor.If it does, resiliency compressible layer can have any thickness, and abrasive grain and specifically chosen decision thickness, composition and/or the selection of durometer of appointed condition.If resiliency compressible layer includes endless belt, then generally use the resiliency compressible layer thickness of about 1 millimeter to about 25 millimeters, but this is not necessarily.

The exemplary materials being applicable to resiliency compressible layer includes elastic foam (such as polyurethane foam), rubber, silicones and combinations thereof.

Abrasive grain has enough hardness and surface roughness, to be used as abrasive grain in process of lapping.

Abrasive grain can be organic granular or inorganic particle.The suitably example of inorganic particle includes aluminium oxide (such as, aloxite (AI2O3), heat treatment aloxite (AI2O3), ceramic alumina, heat treated aluminum), carborundum, titanium diboride, aluminium oxide-zirconium oxide melted material, diamond, boron carbide, ceria, aluminium silicate, cubic boron nitride, garnet, silicon dioxide and combinations thereof.Preferably aloxite (AI2O3) includes by the ExolonESK company (ExolonESKCompany of New York Tuo Nawangda, Tonawanda, N.Y.) or ElectroMinerals company (WashingtonMillsElectroMineralsCorp.) pretreatment of Washington Mil Si and be purchased from those of these companies.Preferably ceramic alumina abrasive grain is included in United States Patent (USP) 4, and 314,827,4,623,364,4,744,802,4,770,671,4,881,951,4,964,883,5,011,508 and 5, those described in 164,348, these patents is all incorporated by reference herein.Other examples of the granule that can be used for the present invention include solid glass ball, hollow glass ball, calcium carbonate, foam of polymers, silicon dioxide and silicate, aluminum trihydrate, mullite and Pumex.

The Organic abrasive particles being applicable to abrasive product is preferably formed by thermoplastic polymer and/or thermosetting polymer.Organic abrasive particles can be formed by thermoplastic, such as Merlon, Polyetherimide, polyester, polrvinyl chloride (PVC), polymethacrylates, polymethyl methacrylate, polyethylene, polysulfones, polystyrene, acrylonitrile butadiene-styrene block copolymer, polypropylene, acetal polymer, polyurethane, polyamide and combinations thereof.Organic abrasive particles can be the mixture of thermoplastic polymer and thermosetting polymer.Other suitable Organic abrasive particles include natural prodcuts, such as shuck.

In some embodiments, the Mohs' hardness of abrasive grain is at least 4, at least 5, at least 6, at least 7 or even at least 8.Exemplary abrasive granule includes shaped abrasive granule (such as shaped ceramic abrasive grain or shaped abrasive composite particles) and the combinations thereof pulverized.

The suitably example of abrasive grain includes: aloxite (AI2O3)；Heat treated aluminum；White fused aluminum oxide；Ceramic alumina aluminum (such as St. Paul, MN 3M company (3MCompany, St.Paul, MN) sell with trade name 3MCERAMICABRASIVEGRAIN those)；Plumbic ocher；Blue alumina；Carborundum (includes green silicon carbide)；Titanium diboride；Boron carbide；Tungsten carbide；Garnet；Titanium carbide；Diamond；Cubic boron nitride；Garnet；Fused alumina zirconia；Ferrum oxide；Chromium oxide；Zirconium oxide；Titanium dioxide；Stannum oxide；Quartz；Anhydrite；Flint；Corundum；Sol-gel derived abrasive grain (such as including the form shaping and pulverizing)；And combinations thereof.Other example includes the shaped abrasive complex of abrasive grain in binder matrix, such as United States Patent (USP) 5, those described in 152,917 (Pieper et al.).These abrasive grains many, aggregate and complex are known in the art.

The example of sol-gel derived abrasive grain and their preparation method is found in United States Patent (USP) 4,314,827 (Leitheiser et al.)；4,623,364 (Cottringer et al.)；4,744,802(Schwabel)；4,770,671 (Monroe et al.)；And 4,881,951 (Monroe et al.).It is contemplated within, abrasive grain can comprise abrasive agglomerates, such as, in United States Patent (USP) 4,652,275 (Bloecher et al.), 4,799,939 (Bloecher et al.), 6,521,004 (Culler et al.) or 6, those described in 881,483 (McArdle et al.).It is further contemplated that abrasive grain can include the polymer beads of Accurate Shaping, this polymer beads comprises organic binder bond and optional abrasive grain, such as in United States Patent (USP) 5, and those described in 714,259 (Holmes et al.).In some embodiments, abrasive grain can use coupling agent (such as, organo silane coupling agent) carry out surface process or carry out other physical treatments (such as ferrum oxide or titanium dioxide), to improve the adhesive force of abrasive grain and binding agent.The pre-treatment abrasive grain can being combined with binding agent at abrasive grain, or on the spot they can be carried out surface process by being covered in binding agent by coupling agent.

Preferably, abrasive grain includes ceramic abrasive particle, the most sol-gel derived polycrystalline alpha alumina particles.Abrasive grain can be to pulverize or shape, or combinations thereof.

Can be according in such as United States Patent (USP) 5,213, method described in 591 (Celikkaya et al.) and US publication application 2009/0165394A1 (Culler et al.) and 2009/0169816A1 (Erickson et al.), utilizes sol-gel precursors alpha alumina particles to prepare the shaped ceramic abrasive grain being made up of the crystallite of alpha-aluminium oxide, magnesium aluminate spinel and rare earth hexa-aluminate.

Shaped ceramic abrasive grain based on alpha-aluminium oxide can be prepared according to known multi-step process.In brief, the method comprises the following steps: what preparation can be changed into alpha-aluminium oxide has crystal seed or the sol gel alphaalumina precursor dispersion without crystal seed；Filling one or more cavity body of mould with sol-gel, this cavity body of mould has the required form of shaped abrasive granule；It is dried sol-gel, to form shaped ceramic abrasive grain precursor；Shaped ceramic abrasive grain precursor is taken out from cavity body of mould；Calcining shapes ceramic abrasive particle precursor, to form the shaped ceramic abrasive grain precursor of calcining, then sinters the shaped ceramic abrasive grain precursor of this calcining, to form shaped ceramic abrasive grain.This technique be will be described in further detail now.

More details about sol-gel derived abrasive grain preparation method are found in such as United States Patent (USP) 4,314,827 (Leitheiser)；5,152,917 (Pieper et al.)；5,435,816 (Spurgeon et al.)；5,672,097 (Hoopman et al.)；5,946,991 (Hoopman et al.)；5,975,987 (Hoopman et al.)；With in 6,129,540 (Hoopman et al.)；And in US publication application 2009/0165394Al (Culler et al.).

Although the shape of shaped ceramic abrasive grain is not particularly limited, but abrasive grain is preferably by utilizing mould to include, and the precursor granules shaping of ceramic precursor material (such as, boehmite collosol and gel) is then formed as reservation shape by sintering.Shaped ceramic abrasive grain can be configured to such as post pyramid, truncated pyramid (such as, butt triangular pyramid) and/or some other regular or irregular polygons.Abrasive grain can include the abrasive agglomerates that a kind of abrasive grain or the abrasive mixture by two or more abrasive materials or two or more abrasive materials are formed.In some embodiments, shaped ceramic abrasive grain is Accurate Shaping, each shaped ceramic abrasive grain will have such shape, and described shape wherein particle-precursors is the shape of a part for the cavity of dry mould or the tool of production before optional calcining and sintering.

The shaped ceramic abrasive grain used in the present invention generally can use instrument (that is, mould) to make, and cutting is accurately processed in use, thus provide and manufacture alternative method (such as, impressing or punching press etc.) higher feature definition than other.Generally, the chamber in tool surfaces has the plane crossed along sharp edges, and forms side and the top of truncated pyramid.The shaped ceramic abrasive grain of gained can have the corresponding nominal average shape corresponding to the chamber shape (such as, truncated pyramid) in tool surfaces；But, the modification (such as, random modification) of nominal average shape can occur in the fabrication process, and the shaped ceramic abrasive grain showing this modification is included in the definition of shaped ceramic abrasive grain used herein.

In some embodiments, pedestal and the top of this shaped ceramic abrasive grain are substantially parallel, obtain prism or truncated pyramid shape, but this is not necessarily.In some embodiments, the sidepiece cutting trigonal pyramid has same size and forms the dihedral angle of about 82 degree with pedestal.It will be appreciated, however, that be used as other dihedral angles (including 90 degree).Such as, the dihedral angle between pedestal and each sidepiece can change independently in the range of 45 to 90 degree, generally changes in the range of 70 to 90 degree, is more typically in the range of 75 to 85 degree and changes.

As used herein, when relating to shaped ceramic abrasive grain, term " length " refers to the full-size of shaped abrasive granule." width " refers to the full-size of the shaped abrasive granule vertical with length.Term " thickness " or " highly " refer to the size of the shaped abrasive granule vertical with length and width.

Preferably, ceramic abrasive particle includes shaped ceramic abrasive grain.The example of sol-gel derived shaping alpha-aluminium oxide (i.e. pottery) abrasive grain is found in United States Patent (USP) 5,201,916 (Berg)；5,366,523(Rowenhorst(Re35,570))；With in 5,984,988 (Berg).United States Patent (USP) 8,034,137 (Erickson et al.) describe alumina abrasive granule, and this alumina abrasive granule is formed with given shape, is then pulverised to form the potsherd retaining a part of original shape feature.In some embodiments, sol-gel derived shaping alpha alumina particles is Accurate Shaping (shape that i.e. granule has at least partly is determined by the shape of the tool of production lumen for preparing them).Details about these abrasive grains and their preparation method are found in such as United States Patent (USP) 8,142,531 (Adefris et al.)；8,142,891 (Culler et al.)；With in 8,142,532 (Erickson et al.)；And U.S. Patent Application Publication 2012/0227333 (Adefris et al.)；2013/0040537 (Schwabel et al.)；With in 2013/0125477 (Adefris).

In some preferred embodiments, abrasive grain includes the shaped ceramic abrasive grain (such as shaping sol-gel derived polycrystalline alpha alumina particles) of generally triangular (such as triangular prism or section trigonal pyramid).

Shaped ceramic abrasive grain is usually chosen to have 1 micron to 15000 microns, more generally 10 microns to about 10000 microns, and still more typically 150 microns to the length in 2600 micrometer ranges, but is used as other length.In some embodiments, this length may be expressed as a part for the thickness that its bonded abrasive being included in is taken turns.Such as, shaped abrasive granule can have the length of half of the thickness taken turns more than this bonded abrasive.In certain embodiments, length can be more than the thickness of bonded abrasives cutting wheel.

Shaped ceramic abrasive grain is usually chosen to have 0.1 micron to 3500 microns, more generally 100 microns to 3000 microns, and still more typically 100 microns to the width in 2600 micrometer ranges, but is used as other length.

Shaped ceramic abrasive grain is usually chosen to have 0.1 micron to 1600 microns, the thickness in more generally 1 micron to 1200 micrometer ranges, but is used as other thickness.

In some embodiments, shaped ceramic abrasive grain can have the aspect ratio (length and the ratio of thickness) of at least 2,3,4,5,6 or bigger.

Face coat on shaped ceramic abrasive grain can be used for improving the adhesion between shaped ceramic abrasive grain and the binding agent in abrasive product, or can help to the electrostatic precipitation of shaped ceramic abrasive grain.In one embodiment, can use United States Patent (USP) 5, the face coat described in 352,254 (Celikkaya), the amount of face coat accounts for the 0.1% to 2% of shaped abrasive particle weight.This type of face coat is in United States Patent (USP) 5,213,591 (Celikkaya et al.)；5,011,508 (Wald et al.)；1,910,444(Nicholson)；3,041,156 (Rowse et al.)；5,009,675 (Kunz et al.)；5,085,671 (Martin et al.)；4,997,461 (Markhoff-Matheny et al.)；And 5,042,991 (Kunz et al.) is described.It addition, face coat can prevent shaped abrasive granule from blocking." block " this term for describing the phenomenon being soldered to shaped ceramic abrasive grain top from the metallic particles of the workpiece being just ground.The face coat realizing above-mentioned functions is known to those skilled in the art.

Independently abrasive grain can be pressed size classes according to the regulation nominal level that Abrasive Industry is generally acknowledged.The grade scale of exemplary Abrasive Industry accreditation includes the standard promulgated by ANSI (American National Standards Institute (ANSI)), FEPA (Europe grinding tool maker alliance) and JIS (Japanese Industrial Standards).ANSI grade name is (i.e., the nominal level specified) include, such as: ANSI4, ANSI6, ANSI8, ANSI16, ANSI24, ANSI36, ANSI46, ANSI54, ANSI60, ANSI70, ANSI80, ANSI90, ANSI100, ANSI120, ANSI150, ANSI180, ANSI220, ANSI240, ANSI280, ANSI320, ANSI360, ANSI400 and ANSI600.FEPA grade name includes F4, F5, F6, F7, F8, F10, F12, F14, F16, F16, F20, F22, F24, F30, F36, F40, F46, F54, F60, F70, F80, F90, F100, F120, F150, F180, F220, F230, F240, F280, F320, F360, F400, F500, F600, F800, F1000, F1200, F1500 and F2000.JIS grade name includes JIS8, JIS12, JIS16, JIS24, JIS36, JIS46, JIS54, JIS60, JIS80, JIS100, JIS150, JIS180, JIS220, JIS240, JIS280, JIS320, JIS360, JIS400, JIS600, JIS800, JIS1000, JIS1500, JIS2500, JIS4000, JIS6000, JIS8000 and JIS10,000.

According to embodiments of the invention, according to FEPA grade F60 to F24, the average diameter of abrasive grain can be in the range of 260 to 1400 microns.

Or, the available U.S.A. standard testing sieve meeting ASTME-11 " for wire screen and the standard specifications of sieve of test purpose " (StandardSpecificationforWireClothandSievesforTestingPurp oses) of abrasive grain is classified to nominal screening class.ASTME-11 defines design and the structure demand of testing sieve, and described testing sieve utilizes the weaving wire screen installed in the frame to classify material according to the granularity specified for medium.Typical case's label can be expressed as-18+20, and it means that abrasive particle by meeting the testing sieve of the ASTME-11 specification of 18 mesh sieves, and can be retained on the testing sieve of the ASTME-11 specification meeting 20 mesh sieves.In one embodiment, abrasive grain has such particle size: most of abrasive grain by 18 mesh testing sieves and can be retained on 20 mesh, 25 mesh, 30 mesh, 35 mesh, 40 mesh, 45 mesh or 50 mesh testing sieves.In multiple embodiments, abrasive grain can have a following nominal screen grade :-18+20 ,-20/+25 ,-25+30 ,-30+35 ,-35+40,5-40+45 ,-45+50 ,-50+60 ,-60+70 ,-70/+80 ,-80+100 ,-100+120 ,-120+140 ,-140+170 ,-170+200 ,-200+230 ,-230+270 ,-270+325 ,-325+400 ,-400+450 ,-450+500 or-500+635.Or, the mesh size of customization, such as-90+100 can be used.

The selected embodiments of the present invention

In the first embodiment, the invention provides a kind of abrasive grain alignment system, including:

The tool of production, including:

Support element, this support element has distribution surface and the back surfaces back to distribution surface, wherein this support element has and is formed at chamber therein, wherein this chamber extends to support element from allocation table facing to back surfaces, the first side wall, the second sidewall, the 3rd sidewall and the 4th sidewall that include at least partially being connected continuously of its lumen, wherein the first side wall and the 3rd sidewall are inwardly tapered the most continuously and contact with each other at straight line, and wherein said second sidewall and the 4th sidewall do not contact each other；And

Abrasive grain, this abrasive grain is disposed entirely within least some chamber removedly.

In this second embodiment, the invention provides the abrasive grain alignment system described in the first embodiment, wherein this abrasive grain is disposed entirely within the chamber of at least 80% removedly.

In the 3rd embodiment, the invention provides the abrasive grain alignment system described in the first or second embodiment, wherein this abrasive grain includes shaped ceramic abrasive grain.

In the 4th embodiment, the invention provides the abrasive grain alignment system described in the 3rd embodiment, wherein at least some of being nominally configured to of this shaped ceramic abrasive grain cuts trigonal pyramid.

In the 5th embodiment, the invention provides the abrasive grain alignment system according to any one of first to fourth embodiment, wherein this abrasive grain comprises polycrystalline alpha-aluminium oxide.

In a sixth embodiment, the invention provides the abrasive grain alignment system according to any one of the first to the 5th embodiment, wherein the first side wall, the second sidewall, the 3rd sidewall and the 4th sidewall are planes.

In the 7th embodiment, the invention provides the abrasive grain alignment system according to any one of the first to the 5th embodiment, wherein at least one of the first side wall, the second sidewall, the 3rd sidewall and the 4th sidewall is convex surface.

In the 8th embodiment, the invention provides the abrasive grain alignment system according to any one of the first to the 7th embodiment, at least some of the including independently of its lumen is arranged on the first inclined-plane distributed between surface and the first side wall and is arranged on the second inclined-plane between distribution surface and the second sidewall, the 3rd inclined-plane being arranged between distribution surface and the 3rd sidewall, and is arranged on the 4th inclined-plane between distribution surface and the 4th sidewall.

In the 9th embodiment, the invention provides the abrasive grain alignment system according to any one of the first to the 8th embodiment, wherein this support element comprises polymer and is flexible.

In the tenth embodiment, the invention provides the abrasive grain alignment system according to any one of the first to the 9th embodiment, wherein this tool of production includes endless belt.

In the 11st embodiment, the invention provides the abrasive grain alignment system according to any one of the first to the tenth embodiment, wherein this tool of production also includes the resiliency compressible layer being fixed to the back surfaces of support element.

In the 12nd embodiment, the invention provides a kind of abrasive grain alignment system, including:

The tool of production, including:

Support element, this support element has distribution surface and the back surfaces back to distribution surface, wherein this support element has and is formed at chamber therein, the most on an individual basis, each chamber the first opening from distribution surface extends to the second opening at back surfaces through support element, and wherein second aperture efficiency the first opening is little；And

Abrasive grain, this abrasive grain is removably disposed at least some chamber so that they do not extend beyond distribution surface.

In the 13rd embodiment, the invention provides the abrasive grain alignment system described in the 12nd embodiment, wherein this abrasive grain is removably disposed in the chamber of at least 80%.

In the 14th embodiment, the invention provides the abrasive grain alignment system described in the 12nd or the 13rd embodiment, wherein this abrasive grain includes shaped ceramic abrasive grain.

In the 15th embodiment, the invention provides the abrasive grain alignment system described in the 14th embodiment, wherein at least some of being nominally configured to of shaped ceramic abrasive grain cuts trigonal pyramid.

In the 16th embodiment, the invention provides the abrasive grain alignment system according to any one of the 14th or the 15th embodiment, wherein this abrasive grain comprises polycrystalline alpha-aluminium oxide.

In the 17th embodiment, the invention provides the abrasive grain alignment system according to any one of the 12nd to the 16th embodiment, wherein:

At least some chamber includes the first side wall, the second sidewall, the 3rd sidewall and the 4th sidewall being connected continuously；

The first side wall and the 3rd sidewall do not contact each other；And

The first side wall and the 3rd sidewall are inwardly tapered towards the second opening from the first opening.

In the 18th embodiment, the invention provides the abrasive grain alignment system described in the 17th embodiment, wherein the second sidewall and the 4th sidewall are inwardly tapered towards the second opening from the first opening.

In the 19th embodiment, the invention provides the abrasive grain alignment system described in the 17th or the 18th embodiment, wherein the first side wall, the second sidewall, the 3rd sidewall and the 4th sidewall are planes.

In the 20th embodiment, the invention provides the abrasive grain alignment system described in the 17th or the 18th embodiment, wherein at least one of the first side wall, the second sidewall, the 3rd sidewall and the 4th sidewall is convex surface.

In the 21st embodiment, the invention provides the abrasive grain alignment system according to any one of the 17th to the 20th embodiment, at least some of first inclined-plane including independently being arranged between distribution surface and the first side wall of its lumen, and it is arranged on the second inclined-plane between distribution surface and the second sidewall, it is arranged on the 3rd inclined-plane between distribution surface and the 3rd sidewall, and is arranged on the 4th inclined-plane between distribution surface and the 4th sidewall.

In the 22nd embodiment, the invention provides the abrasive grain alignment system according to any one of the 12nd to the 21st embodiment, wherein at least some of being nominally configured to of this abrasive grain cuts trigonal pyramid.

In the 23rd embodiment, the invention provides the abrasive grain alignment system according to any one of the 12nd to the 22nd embodiment, wherein this support element comprises polymer and is flexible.

In the 24th embodiment, the invention provides the abrasive grain alignment system according to any one of the 12nd to the 23rd embodiment, wherein this tool of production includes endless belt.

In the 25th embodiment, the invention provides the abrasive grain alignment system according to any one of the 12nd to the 24th embodiment, wherein this tool of production also includes the resiliency compressible layer being fixed to the back surfaces of support element.

In the 26th embodiment, the invention provides the abrasive grain alignment system described in the 25th embodiment, wherein this resiliency compressible layer includes profiled recess, this profiled recess respectively orientation alignment chamber at least some of in second opening in each chamber.

In the 27th embodiment, the invention provides the abrasive grain alignment system described in the 25th embodiment, wherein this resiliency compressible layer includes compressible conduit, at least one of second opening in this compressible conduit orientation alignment chamber respectively, and wherein this compressible conduit extends through resiliency compressible layer.

In the 28th embodiment, present invention provide for abrasive grain is placed exactly in the suprabasil tool of production of binding agent, this tool of production includes:

Resiliency compressible layer, this resiliency compressible layer is fixed to the back surfaces of support element.

In the 29th embodiment, the invention provides described in the 28th embodiment for abrasive grain being placed exactly in the suprabasil tool of production of binding agent, wherein this resiliency compressible layer includes profiled recess, this profiled recess respectively orientation alignment chamber at least some of in each the second opening.

In the 30th embodiment, the invention provides described in the 28th embodiment for abrasive grain being placed exactly in the suprabasil tool of production of binding agent, wherein this resiliency compressible layer includes compressible conduit, at least one of second opening in this compressible conduit orientation alignment chamber respectively, and wherein this compressible conduit extends through resiliency compressible layer.

In the 31st embodiment, the invention provides according to any one of the 28th to the 30th embodiment for abrasive grain being placed exactly in the suprabasil tool of production of binding agent, wherein:

The first side wall and the 3rd sidewall do not contact each other；And

In the 32nd embodiment, the invention provides described in the 31st embodiment for abrasive grain being placed exactly in the suprabasil tool of production of binding agent, wherein the first side wall, the second sidewall, the 3rd sidewall and the 4th sidewall are planes.

In the 33rd embodiment, the invention provides described in the 31st embodiment for abrasive grain being placed exactly in the suprabasil tool of production of binding agent, wherein at least one of the first side wall, the second sidewall, the 3rd sidewall and the 4th sidewall is convex surface.

In the 34th embodiment, the invention provides according to any one of the 31st to the 33rd embodiment for abrasive grain being placed exactly in the suprabasil tool of production of binding agent, at least some of first inclined-plane including independently being arranged between distribution surface and the first side wall of its lumen, and it is arranged on the second inclined-plane between distribution surface and the second sidewall, it is arranged on the 3rd inclined-plane between distribution surface and the 3rd sidewall, and is arranged on the 4th inclined-plane between distribution surface and the 4th sidewall.

In the 35th embodiment, the invention provides according to any one of the 28th to the 34th embodiment for abrasive grain being placed exactly in the suprabasil tool of production of binding agent, wherein this support element comprises polymer and is flexible.

In the 36th embodiment, the invention provides according to any one of the 28th to the 35th embodiment for abrasive grain being placed exactly in the suprabasil tool of production of binding agent, wherein this support element includes endless belt.

In the 37th embodiment, the present invention is provided to abrasive grain is placed exactly in the suprabasil tool of production of binding agent, this tool of production includes having distribution surface and the support element of the back surfaces back to distribution surface, wherein this support element has and is formed at chamber therein, and wherein this support element includes the machine-direction oriented raised feet component that at least two is arranged on distribution surface.

In the 38th embodiment, the invention provides described in the 37th embodiment for abrasive grain being placed exactly in the suprabasil tool of production of binding agent, at least one of the raised feet component that at least two of which is machine-direction oriented is continuous print.

In the 39th embodiment, the invention provides described in the 37th or 38 embodiments for abrasive grain being placed exactly in the suprabasil tool of production of binding agent, wherein this allocation table mask has the first opposite side along its length and the second opposite side, the machine-direction oriented raised feet component of at least two of which includes the first machine-direction oriented raised feet component and the second machine-direction oriented raised feet component, wherein the first machine-direction oriented raised feet component is adjacent to distribute first limit on surface, and the second machine-direction oriented raised feet component is adjacent to distribute first limit on surface.

In the 40th embodiment, the invention provides described in the the 30th the seven to three ten nine embodiment for abrasive grain being placed exactly in the suprabasil tool of production of binding agent, the machine-direction oriented raised feet component of at least two of which includes the first machine-direction oriented raised feet component and the second machine-direction oriented raised feet component, the machine-direction oriented raised feet component of at least two of which also includes being arranged between the first machine-direction oriented raised feet component and the second machine-direction oriented raised feet component and be parallel to the first machine-direction oriented raised feet component and the 3rd machine-direction oriented raised feet component of the second machine-direction oriented raised feet component.

In the 41st embodiment, the invention provides described in the 30th seven to four ten embodiment for abrasive grain being placed exactly in the suprabasil tool of production of binding agent, its lumen extends to support element from allocation table facing to back surfaces, the first side wall including at least partially being connected of its lumen, the second sidewall, the 3rd sidewall and the 4th sidewall.

In the 42nd embodiment, the invention provides described in the 41st embodiment for abrasive grain being placed exactly in the suprabasil tool of production of binding agent, wherein the first side wall and the 3rd sidewall are inwardly tapered the most continuously and contact with each other at straight line.

In the 43rd embodiment, the invention provides described in the 41st embodiment for abrasive grain being placed exactly in the suprabasil tool of production of binding agent, wherein the second sidewall and the 4th sidewall do not contact each other.

In the 44th embodiment, the invention provides according to any one of the 41st to the 43rd embodiment for abrasive grain being placed exactly in the suprabasil tool of production of binding agent, wherein the first side wall, the second sidewall, the 3rd sidewall and the 4th sidewall are planes.

In the 45th embodiment, the invention provides according to any one of the 41st to the 43rd embodiment for abrasive grain being placed exactly in the suprabasil tool of production of binding agent, wherein at least one of the first side wall, the second sidewall, the 3rd sidewall and the 4th sidewall is convex surface.

In the 46th embodiment, the invention provides according to any one of the 41st to the 45th embodiment for abrasive grain being placed exactly in the suprabasil tool of production of binding agent, at least some of first inclined-plane including independently being arranged between distribution surface and the first side wall of its lumen, and it is arranged on the second inclined-plane between distribution surface and the second sidewall, it is arranged on the 3rd inclined-plane between distribution surface and the 3rd sidewall, and is arranged on the 4th inclined-plane between distribution surface and the 4th sidewall.

In the 47th embodiment, the invention provides according to any one of the 37th to the 46th embodiment for abrasive grain being placed exactly in the suprabasil tool of production of binding agent, wherein this support element comprises polymer and is flexible.

In the 48th embodiment, the invention provides according to any one of the 37th to the 47th embodiment for abrasive grain being placed exactly in the suprabasil tool of production of binding agent, wherein this tool of production includes endless belt.

In the 49th embodiment, the invention provides according to any one of the 37th to the 48th embodiment for abrasive grain being placed exactly in the suprabasil tool of production of binding agent, also include the resiliency compressible layer being fixed to the back surfaces of support element.

In the 50th embodiment, the invention provides described in the 49th embodiment for abrasive grain being placed exactly in the suprabasil tool of production of binding agent, wherein this resiliency compressible layer includes profiled recess, this profiled recess respectively orientation alignment chamber at least some of in each the second opening.

In the 51st embodiment, the invention provides described in the 49th embodiment for abrasive grain being placed exactly in the suprabasil tool of production of binding agent, wherein this resiliency compressible layer includes compressible conduit, at least one of second opening in this compressible conduit orientation alignment chamber respectively, and wherein this compressible conduit extends through resiliency compressible layer.

In the 52nd embodiment, the invention provides a kind of coated abrasives draft machine equipment, including:

In the 53rd embodiment, the invention provides the coated abrasives draft machine equipment described in the 52nd embodiment, wherein this tool of production includes support element, this support element has distribution surface and the back surfaces back to distribution surface, wherein this support element has and is formed at multiple chamber therein, plurality of chamber extends to support element from allocation table facing to back surfaces, the first side wall including at least partially being connected continuously in plurality of chamber, second sidewall, 3rd sidewall and the 4th sidewall, wherein the first side wall and the 3rd sidewall are inwardly tapered the most continuously and contact with each other at straight line, and wherein the second sidewall and the 4th sidewall do not contact each other.

In the 54th embodiment, the invention provides the coated abrasives draft machine equipment described in the 52nd embodiment, wherein this tool of production includes support element, this support element has distribution surface and the back surfaces back to distribution surface, wherein this support element has and is formed at multiple chamber therein, the most on an individual basis, each chamber the first opening from distribution surface extends to the second opening at back surfaces through support element, and wherein second aperture efficiency the first opening is little.

In the 55th embodiment, the invention provides the coated abrasives draft machine equipment described in the 52nd embodiment, wherein this tool of production includes support element, and this support element has distribution surface, back to the back surfaces on distribution surface and be fixed to the resiliency compressible layer of back surfaces of support element；And wherein this support element has and is formed at multiple chamber therein, the most on an individual basis, each chamber the first opening from distribution surface extends to the second opening at back surfaces through support element, and wherein second aperture efficiency the first opening is little.

In the 56th embodiment, the invention provides the coated abrasives draft machine equipment described in the 55th embodiment, wherein this resiliency compressible layer includes multiple hole, and align with a chamber in each of which hole so that opening extends through support element and through resiliency compressible layer from distribution surface.

In the 57th embodiment, the invention provides the coated abrasives draft machine equipment described in the 52nd embodiment, wherein this tool of production includes support element, this support element has distribution surface and the back surfaces back to distribution surface, wherein this support element has and is formed at chamber therein, and wherein this support element includes the machine-direction oriented raised feet component that at least two is arranged on distribution surface.

In the 58th embodiment, the invention provides the coated abrasives draft machine equipment according to any one of the 52nd to the 57th embodiment, it includes filling auxiliary part, this filling auxiliary part is positioned between abrasive grain transferring roller and abrasive grain feeder along the direction that the first web path is advanced with the tool of production, to be moved in chamber by the abrasive grain on distribution surface.

In the 59th embodiment, the invention provides the coated abrasives draft machine equipment described in the 58th embodiment, wherein this filling auxiliary part includes brush.

In the 60th embodiment, the invention provides the coated abrasives draft machine equipment according to any one of the 52nd to the 59th embodiment, it includes abrasive grain removing components, this abrasive grain removing components is positioned between abrasive grain transferring roller and abrasive grain feeder along the direction that the first web path is advanced with the tool of production, to remove excess abrasive grain from this distribution surface.

In the 61st embodiment, the invention provides the coated abrasives draft machine equipment described in the 60th embodiment, wherein this abrasive grain removing components includes air knife, to blow away excess abrasive grain from this distribution surface.

In the 62nd embodiment, the invention provides the coated abrasives draft machine equipment according to any one of the 52nd to the 61st embodiment, wherein this distribution surface is at the rear-inclined of abrasive grain feeder so that the height in multiple chambeies increases along the direction that the first web path is advanced with the tool of production.

In the 63rd embodiment, the invention provides the coated abrasives draft machine equipment according to any one of the 52nd to the 62nd embodiment, wherein when the tool of production is wound on abrasive grain transferring roller, this distribution surface is squeezed.

In the 64th embodiment, the invention provides the coated abrasives draft machine equipment according to any one of the 52nd to the 63rd embodiment, wherein vibration source is connected to abrasive grain transferring roller.

In the 65th embodiment, the invention provides the coated abrasives draft machine equipment described in the 54th embodiment, wherein this abrasive grain transferring roller has the excircle of elastomer.

In the 66th embodiment, the invention provides the coated abrasives draft machine equipment described in the 54th embodiment, wherein having multiple hole in the excircle of this abrasive grain transferring roller, the plurality of hole connects with the internal pressurization air fluid being included in abrasive grain transferring roller.

In the 67th embodiment, the invention provides the coated abrasives draft machine equipment described in the 54th embodiment, it vacuum tank including being positioned adjacent to back surfaces, this vacuum tank is located proximate to abrasive grain feeder.

In the 68th embodiment, the invention provides a kind of coated abrasives draft machine equipment, including:

In the 69th embodiment, the invention provides the coated abrasives draft machine equipment described in the 68th embodiment, wherein this tool of production includes the sleeve pipe being positioned on the excircle of abrasive grain transferring roller.

In the 70th embodiment, the invention provides the coated abrasives draft machine equipment described in the 68th embodiment, on the outer surface of abrasive grain transferring roller, wherein form multiple chamber.

In the 71st embodiment, the invention provides the coated abrasives draft machine equipment according to any one of the 68th to the 70th embodiment, wherein this abrasive grain feeder is oriented to be assigned to abrasive grain distribute on surface before the top dead-centre of this abrasive grain transferring roller relative to the direction of rotation of this abrasive grain transferring roller.

In the 72nd embodiment, the invention provides the coated abrasives draft machine equipment described in the 71st embodiment, it includes that abrasive grain keeps component, it is adjacent with distribution surface that this abrasive grain keeps component to be oriented to, and relative to the direction of rotation of abrasive grain transferring roller before the top dead-centre of abrasive grain transferring roller, to stop freely the dropping of abrasive grain being supplied to distribution surface by abrasive grain feeder.

In the 73rd embodiment, the invention provides the coated abrasives draft machine equipment described in the 72nd embodiment, wherein abrasive grain keeps component to include hang plate, so that excess abrasive grain landing.

By following non-limiting example, further illustrate objects and advantages of the present invention, but the concrete material quoted in these embodiments and amount thereof and other condition and details are not construed as the improper restriction to the present invention.

Embodiment

Except as otherwise noted, otherwise all numbers in the remainder of embodiment and this specification, percent, ratio etc. are by weight.

Embodiment 1-2 and Comparative examples A-B

The fiber disc hereinafter described prepared according to the coated abrasives of embodiment 1 and embodiment 2 and Comparative examples A and comparative example B and test.

Embodiment 1

Disclosure preparation according to United States Patent (USP) 8,142,531 (Adefris et al.) shapes abrasive grain.By the length of side 0.110 inch (2.8mm), die depth 0.028 inch (0.71mm) equilateral triangular shape polypropylene molds cavity in patterned Indium Alumina gel gel prepare shaping abrasive grain.Fired shaped abrasive granule is about 1.37mm (length of side) × 0.027mm thickness and will be sieved by ASTM16 (being equal to Tyler14) purpose.

The preparation method of primer layer resin is: mix 49 parts of fusible phenolic resin (base catalysis condensates, phenol: the mol ratio of formaldehyde is 1.5:1 to 2.1:1), 41 parts of calcium carbonate (HUBERCARB, Illinois Quincy Hans Huber engineering material company (HuberEngineeredMaterials, Quincy, IL)), add 10 parts of water and mix.Then via brush to the vulcanised fibre web (DYNOSVULCANIZEDFIBRE thick for 7 inches of (17.8cm) diameters × 0.83mm with 0.875 inch of (2.22cm) centre bore, DYNOS company (the DYNOSGmbH of Troisdorf, Germany, Troisdorf, Germany)) apply 3.8 grams of these mixture.

Then under rapping assistance, in the tool of production, fill shaped abrasive granule, this tool of production has (length direction spacing=1.978mm that generally construct as shown in figs. 3 a-3 c, that arrange with rectangular array, width spacing=0.886mm, all long sizes are with a direction) triangle open mouth that is vertically oriented (wherein length=1.875mm, width=0.785mm, the degree of depth=1.62mm, bottom width=0.328mm).Brush removal is used to exceed the excessive shaped abrasive granule being received in tool cavity.Then by the tool of production band containing shaped abrasive granule to very close to the place of adhesive coating dish aligned, the tool of production is inverted with by shaped abrasive granule with the pattern deposition of precise distance and orientation on adhesive coating dish.Every cm²Use about 57 granules.

The weight of the shaped abrasive granule transferring to each dish is 7.3 grams.Be heating and curing primer layer resin (at 70 DEG C 45 minutes, at 90 DEG C 45 minutes, then at 105 DEG C 3 hours).Then to the conventional phenolic aldehyde re-glue resin containing cryolite of each dish coating and solidify (at 70 DEG C 45 minutes, at 90 DEG C 45 minutes, then at 105 DEG C 3 hours).Then to the coating of each dish conventional containing KBF₄Top gum resin and solidify (at 70 DEG C 45 minutes, at 90 DEG C 45 minutes, then at 105 DEG C 15 hours).

Completed belt figure layer mill is allowed to balance 1 week under ambient humidity, then balance 2 days under 50%RH before test.Table 1 reports the result from abrasive disc test.

Embodiment 2

The preparation method of the abrasive product of embodiment 2 is same as in Example 1, and except for the difference that the tool of production has the forming cavity being perpendicular to radial direction with rule radial arrays layout and length direction.Therefore every cm²Use about 38 granules.

Comparative examples A

Comparative examples A is the fiber disc containing the ceramic alumina aluminum particulate pulverized, trade name 3M985C fiber disc, grade 36,7 inches, purchased from St. Paul, MN 3M company (3MCompany, SaintPaul, MN).

Comparative example B

Comparative example B is the fiber disc of the shaped abrasive granule containing ceramic alumina, trade name 3M987C fiber disc, grade 36+, 7 inches, purchased from 3M company (3MCompany).

Abrasive disc is tested

Abrasive disc test simulation abrasive material effect, to polish bead and to be mixed into workpiece.6.5 inches (16.5cm) red ribbed backing plate (3M part number 051144-80514) is used to be arranged on right-angle grinder (CLECO1760BVL, 3HP) by 7 inches of (18cm) fiber diameters dishes to be evaluated.Workpiece is that preweighted rustless steel is to (304L plate, 6 inches of (15.2cm) × 12 inch (30.5cm) × 3/8 inch (0.95cm) are thick), not oil-containing and firecoat.Fix one of them stainless steel work-piece, it is used for grinding with the face of 6 inches of (15.2cm) × 12 inch (30.5cm) of exposure, fix another stainless steel work-piece, be used for grinding exposing the face of 3/8 inch of (0.95cm) × 12 inch (30.5cm).Start right-angle grinder, and abrasive disc is pressed in 6 inches of (15.2cm) × 12 inch (30.5cm) face upper 45 seconds, be then pressed in 3/8 inch of (0.95cm) × 12 inch (30.5cm) face upper 15 second.Again weigh workpiece pair, grinding, to determine, the quantity of material being removed in circulation for the first time, then cool down in water workpiece to and be dried.Then this grinding circulation is repeated, until the quantity of material being removed is to grind the 50% of circulation for the first time.Test result is reported with cutting output (removing the grams of metal) and test loop number of times.

Table 1

Embodiment 3-5 and comparative example C

Embodiment 3-5 and comparative example C are coated abrasive band, and according to hereinafter described preparing and testing.

Embodiment 3

nullUse by 75 parts of EPON828 epoxy resin (bisphenol A diglycidyl ethers，Purchased from Houston, Texas superior product company (ResolutionPerformanceProducts with keen determination,Houston,TX))、10 parts of trimethylolpropane trimethacrylates are (with title SR351 purchased from Wood orchid park, New Jersey Qing Te industrial group (CytecIndustrialInc.,WoodlandPark,NJ))、8 parts of dicy-curing agents are (with title DICYANEX1400B purchased from Pennsylvania Alan gas ballast air chemical products company (AirProductsandChemicals,Allentown,PA))、5 parts of novolac resins are (with title RUTAPHEN8656 purchased from Columbus, Ohio Mai Tu specialty chemicals company (MomentiveSpecialtyChemicalsInc.,Columbus,OH))、1 part 2,2-dimethoxy-2-phenyl acetophenone is (with title IRGACURE651 light trigger purchased from New Jersey not Lip river Farnham Parker BASF AG (BASFCorp.,FlorhamPark,) and 0.75 part of 2-propyl imidazole is (with title ACTIRONNXJ-60LIQUID purchased from North Carolina state Mo Gendun Xian Chuan company (Synthron NJ),Morganton,NC) compositions) formed is 300 to 400 grams every square metre (g/m to weight²) untreated mylar (with trade name POWERSTRAIT purchased from Spartanburg, South Carolina Milliken Co. (Milliken&Company, Spartanburg, SC)) carry out pre-gluing.10.16cm × 114.3cm band of this backing is adhered on the thick lamination granule sheet material of 15.2cm × 121.9cm × 1.9cm.Cloth backing is coated with by 52 parts of fusible phenolic resin (with title GP8339R-23155B purchased from Atlanta, Georgia Georgia-Pacific chemical company (GeorgiaPacificChemicals, Atlanta, GA)), 45 parts of calcium metasilicates are (with title WOLLASTOCOAT purchased from New York Weir Si Baoluo Nyco SA (NYCOCompany, Willsboro, NY)) and the 183g/m of 2.5 parts of water compositions²Phenolic aldehyde primer layer resin, painting method is filled backing fabric for using putty knife and removes excess resin.nullBy abrasive grain (according to United States Patent (USP) 8,142,Shaped abrasive granule prepared by the disclosure of 531 (Adefris et al.)，There is the 1.30mm side edge length that nominal is equal、0.27mm thickness and 98 degree of Sidewall angles) it is filled in the tool of production of 6.35cm × 10.16cm，This tool of production has generally by constructing as shown in figs. 3 a-3 c、(length direction spacing=the 2.68mm arranged with rectangular array，Width spacing=1.075mm)、And its long size is aligned in a series of triangle open mouth (wherein length=1.698mm being vertically oriented at relative to 2 degree of angles of backing longitudinal size，Width=0.621mm，The degree of depth=1.471mm，Bottom width=0.363mm)，And use vibration and brush to remove excess mineral.Long end is arranged by 11 long ends of these instruments and is installed on the thick granule sheet material of second 15.2cm × 121.9cm × 1.9cm, to guarantee to generate the abrasive coating band of at least 111cm.On two lamination granule sheet materials at the about 2.54cm of the every one end of distance and the midpoint of 15.2cm size gets out the hole of 1.0cm diameter through thickness.Construct the pedestal that every one end has the vertical pin of 0.95cm diameter, to engage the hole in granule sheet material, thus the position (open side is upwards) of the abrasive grain fill tool that first aligns, then the backing (coated side is downward) of primer layer resin coating of aliging.Several spring perches are attached to granule sheet material structure to be kept together.Clamp assembly is removed from pin, turns (present backing coated side is upwards and instrument open side is downward) and put back to pedestal (using pin to keep alignment).Hammer is used to repeat to rap the back of lamination granule sheet material, at about 35 abrasive grain/cm²Lower abrasive grain is transferred to primer layer coating backing.Remove spring perch and from pin, be carefully removed top sheet material so that the mineral of transfer does not strikes the beam on side.Remove band, and abrasive coating backing is placed in the baking oven of 90 DEG C 1.5 hours, with partially cured primer layer resin.nullBy 29.42 parts of fusible phenolic resin (with title GP8339R-23155B purchased from Atlanta, Georgia Georgia-Pacific chemical company (GeorgiaPacificChemicals on Shua,Atlanta,GA))、18.12 part water、50.65 parts of cryolites are (with title RTN cryolite purchased from Houston, Texas TR International trade company (TRInternationalTradingCo.,Houston,TX))、59 parts of 40 grades of FRPL plumbic ochers are (purchased from Austria Villavh TreibacherSchleifmittelAG company (TreibacherSchleifmittelAG,Villach,) and 1.81 parts of surfactants are (with title EMULONA purchased from Fructus Canarii albi mountain, New Jersey BASF AG (BASFCorp. Austria),MountOlive,NJ) the re-glue resin (756g/m) formed²), and coated tape is placed in the baking oven of 90 DEG C 1 hour, the final solidification of 8 hours is then carried out at 102 DEG C.After solidification, use conventional adhesive bonding operation that coated abrasive band is converted into band.

Embodiment 4

The preparation method of embodiment 4 is same as in Example 3, and except for the difference that tool cavity is positioned as its long dimension orthogonal in the long size of backing.

Embodiment 5

Embodiment 5 is the repetition of embodiment 4.

Abrasive belts is tested

Abrasive belts test is for evaluating creative and effect of contrast abrasive belts.The size treating measuring tape is 10.16cm × 91.44cm.Workpiece is 304 stainless steel strips, and provides abrasive belts along its 1.9cm × 1.9cm end.We used a diameter of 20.3cm, durometer records the rubber contact wheel of the band sawtooth (cross section is 1:1 with the ratio of groove) that Durometer A hardness is 70.Band is driven to 5500SFM.This workpiece defeats the core at band with the mixing normal direction of 10 pounds to 15 pound (4.53kg to 6.8kg).This test includes measuring workpiece weight loss of (1 circulation) after grinding 15 seconds.Then by workpiece cooling and again test.Test is terminated after 60 test loop.Record cutting output (gram) after circulation every time.Test result record (under) in table 2.

Table 2

In the patent application of patent certificate achieved above, the list of references of all references, patent or patent application full text or specified portions in a uniform matter are incorporated herein by reference.In the case of there is inconsistent or contradiction between the part and the application of the list of references being incorporated to, should be as the criterion with the information in preceding description.In order to make that those skilled in the art are capable of claimed invention and given preceding description should not be construed as limiting the scope of the present invention, the scope of the present invention is limited by claims and all equivalents thereof.

Claims

1. a draft machine equipment for coated abrasives, including:

First web path, described first web path is for having the tool of production on the distribution surface including multiple chamber, described first web path guides the described tool of production draft machine equipment by described coated abrasives so that a part for the excircle of described tool of production winding abrasive grain transferring roller；

Second web path, described second web path is for the backing of resin coating, described second web path guides the backing of the described resin coating draft machine equipment by described coated abrasives, the backing that described resin is coated winds a part for the described excircle of described abrasive grain transferring roller, and the resin bed of the backing of wherein said resin coating is positioned at towards described distribution surface alignment and the described tool of production between backing and the described excircle of described abrasive grain transferring roller of the coating of described resin；With

Abrasive grain feeder, described abrasive grain feeder the described tool of production along described first web path advance direction on be positioned at described abrasive grain transferring roller before, abrasive grain be assigned on described distribution surface and to be assigned in the plurality of chamber；And

Wherein when the backing that described resin coats and the described tool of production turn round around described abrasive grain transferring roller, abrasive grain is transferred to the backing of described resin coating from the plurality of chamber.

The draft machine equipment of coated abrasives the most according to claim 1, the wherein said tool of production includes having described distribution surface and the support element of the back surfaces back to described distribution surface, wherein said support element has and is formed at the plurality of chamber therein, wherein said multiple chamber extends to described support element from described allocation table facing to described back surfaces, the first side wall including at least partially being connected continuously in wherein said multiple chamber, second sidewall, 3rd sidewall and the 4th sidewall, wherein said the first side wall and described 3rd sidewall are inwardly tapered the most continuously and contact with each other at straight line, and wherein said second sidewall and described 4th sidewall do not contact each other.

The draft machine equipment of coated abrasives the most according to claim 1, the wherein said tool of production includes having described distribution surface and the support element of the back surfaces back to described distribution surface, wherein said support element has and is formed at the plurality of chamber therein, the most on an individual basis, each described chamber the first opening from described distribution surface extends to the second opening at described back surfaces through described support element, and the first opening described in wherein said second aperture efficiency is little.

The draft machine equipment of coated abrasives the most according to claim 1, the wherein said tool of production includes having described distribution surface, back to the back surfaces on described distribution surface and be fixed to the support element of resiliency compressible layer of described back surfaces of described support element；And wherein said support element has and is formed at the plurality of chamber therein, the most on an individual basis, each described chamber the first opening from described distribution surface extends to the second opening at described back surfaces through described support element, and the first opening described in wherein said second aperture efficiency is little.

The draft machine equipment of coated abrasives the most according to claim 4, wherein said resiliency compressible layer includes multiple hole, and the most each described hole is directed at a chamber in described chamber so that opening extends through described support element and through described resiliency compressible layer from described distribution surface.

The draft machine equipment of coated abrasives the most according to claim 1, the wherein said tool of production includes having described distribution surface and the support element of the back surfaces back to described distribution surface, wherein said support element has and is formed at chamber therein, and the raised feet component that the wherein said support element at least two that includes being arranged on described distribution surface is machine-direction oriented.

7. according to the draft machine equipment of coated abrasives in any one of the preceding claims wherein, it includes filling auxiliary part, described filling auxiliary part is positioned between described abrasive grain transferring roller and described abrasive grain feeder, to be moved in described chamber by the abrasive grain on described distribution surface on the direction that described first web path is advanced at the described tool of production.

The draft machine equipment of coated abrasives the most according to claim 7, wherein said filling auxiliary part includes brush.

9. according to the draft machine equipment of coated abrasives in any one of the preceding claims wherein, it includes abrasive grain removing components, described abrasive grain removing components is positioned between described abrasive grain transferring roller and described abrasive grain feeder on the direction that described first web path is advanced at the described tool of production, to remove excess abrasive grain from described distribution surface.

The draft machine of coated abrasives the most according to claim 9, wherein said abrasive grain removing components includes air knife, to blow away excess abrasive grain from described distribution surface.

11. according to the draft machine equipment of coated abrasives in any one of the preceding claims wherein, wherein said distribution surface is at the rear-inclined of described abrasive grain feeder so that the height in the plurality of chamber increases on the direction that described first web path is advanced at the described tool of production.

12. according to the draft machine equipment of coated abrasives in any one of the preceding claims wherein, and wherein when the described tool of production is wound on described abrasive grain transferring roller, described distribution surface is squeezed.

13. according to the draft machine equipment of coated abrasives in any one of the preceding claims wherein, and wherein vibration source is connected to described abrasive grain transferring roller.

The draft machine of 14. coated abrasives according to claim 3, wherein said abrasive grain transferring roller has elastomer excircle.

The draft machine of 15. coated abrasives according to claim 3, wherein said abrasive grain transferring roller has multiple hole in described excircle, and the plurality of hole connects with the internal pressurization air fluid being included in described abrasive grain transferring roller.

The draft machine of 16. coated abrasives according to claim 3, it includes and the vacuum tank of described back surfaces adjacent positioned, and described vacuum tank is positioned near described abrasive grain feeder.

The draft machine equipment of 17. 1 kinds of coated abrasives, including:

The tool of production, the described tool of production is positioned on the excircle of abrasive grain transferring roller, and the described tool of production has distribution surface, and described allocation table mask has multiple chamber；

Web path for the backing of resin coating, described web path guides the backing of described resin coating by described coated abrasives draft machine equipment, the backing that described resin is coated winds a part for the described excircle of described abrasive grain transferring roller, and the resin bed of the backing of wherein said resin coating is towards described distribution surface alignment；With

Abrasive grain feeder, abrasive grain is assigned on described distribution surface and is assigned in the plurality of chamber by it；And

(in addition) draft machine of coated abrasives according to claim 17, the draft machine of described coated abrasives has the web path preventing any contact between described distribution surface and support element.

The draft machine of 18. coated abrasives according to claim 17, the wherein said tool of production includes the sleeve pipe being positioned on the described excircle of described abrasive grain transferring roller.

The draft machine of 19. coated abrasives according to claim 17, wherein said multiple chambeies are formed in the described outer surface of described abrasive grain transferring roller.

20. according to the draft machine of the coated abrasives described in claim 17,18 or 19, and wherein said abrasive grain feeder is oriented to be assigned to by abrasive grain on described distribution surface before the top dead-centre of described abrasive grain transferring roller relative to the direction of rotation of described abrasive grain transferring roller.

The draft machine of 21. coated abrasives according to claim 20, it includes that abrasive grain keeps component, described abrasive grain keep component be positioned to adjacent with described distribution surface and relative to the direction of rotation of described abrasive grain transferring roller before the top dead-centre of described abrasive grain transferring roller, to stop freely the dropping of abrasive grain being supplied to described distribution surface by described abrasive grain feeder.

The draft machine of 22. coated abrasives according to claim 21, wherein said abrasive grain keeps component to include hang plate, so that excess abrasive grain landing.